Alzahombre Plataforma Aérea

Service and Maintenance Manual
Model
E300A
E300AJ
E300AJP
P/N - 3120772
January 23, 2009

INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A GENERAL C MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
sonnel pay strict attention to these warnings and precau- THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
tions to avoid possible injury to themselves or others, or INJURY OR DEATH AND IS A SAFETY VIOLATION.
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate. • ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS
OR COMPONENTS.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS
ING ELECTRICAL STORMS. ENSURE THAT FUEL CAP
SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.
IS CLOSED AND SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during mainte- • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN
nance are inserted at the appropriate point in the manual. PERFORMING ANY MAINTENANCE.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
parts. LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
Your safety, and that of others, is the first consideration IN EQUIPMENT.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS
parts without the aid of a mechanical device. Do not allow ON MACHINE AND IN SERVICEMANUAL.
heavy objects to rest in an unstable position. When raising • KEEP OIL, GREASE, WATER, ETC. WIPED FROM
a portion of the equipment, ensure that adequate support STANDING SURFACES AND HAND HOLDS.
is provided.
• USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- • NEVER WORK UNDER AN ELEVATED BOOM UNTIL
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR. MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR
BOOM SAFETY PROP HAS BEEN ENGAGED.
B HYDRAULIC SYSTEM SAFETY • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
It should be noted that the machines hydraulic systems PERFORMING ANY OTHER MAINTENANCE, SHUT
operate at extremely high potentially dangerous pres- OFF ALL POWER CONTROLS.
sures. Every effort should be made to relieve any system • BATTERY SHOULD ALWAYS BE DISCONNECTEDDUR-
pressure prior to disconnecting or removing any portion of ING REPLACEMENT OF ELECTRICAL COMPONENTS.
the system.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
Relieve system pressure by cycling the applicable control MENTS STOWED IN THEIR PROPER PLACE.
several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure • USE ONLY APPROVED, NONFLAMMABLE CLEANING
feed lines to system components can then be discon- SOLVENTS.
nected with minimal fluid loss.
3120772 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
Original Issue November 15, 2000

Revised October 1, 2001
Revised April 10, 2002
Revised June 4, 2002
Revised November 3, 2006
Revised January 14, 2008
Revised January 23, 2009
A-2 – JLG Lift – 3120772

TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.6 Hydraulic Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.7 Hydraulic Pump/Electric Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.8 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.9 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.10 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.11 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.12 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.13 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.14 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.15 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.16 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
3120772 – JLG Lift – i

TABLE OF CONTENTS

Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-6
SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires and Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Drive Hub Part No. 2780236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Disassembly of Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Disassembly of the first stage planetary assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Disassembly of second stage planet gears (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Assembly of first stage planetary assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Assembly of end cover unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Initial Start-up And After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Oil Change Interval-Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Drive Hub (S/N 115723 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Output Planet Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Output Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Hub-Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Cover Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.4 Drive Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.5 Speed Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.6 Positrac/Tilt module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3.7 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Replacement of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Swing Bearing Torque Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Checking Worm Gear End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Adjusting End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.8 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Shaft Timing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.9 Helac Rotary actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Tools Required for Assembly/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
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TABLE OF CONTENTS

3.10 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Battery Maintenance, Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Charging Sequence of Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
SECTION 4 - BOOM & PLATFORM
4.1 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Removal of the Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Disassembly of the Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Assembly of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Installation of the Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.3 Articulating Jib (AJ/AJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Tilt Indicator Switch Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.5 Footswitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.6 Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
SECTION 5 - HYDRAULICS
5.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Cup and Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Systems Incorporating Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Cylinder Without Counterbalance Valves (Steer and Master) . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cylinders With Single Counterbalance Valve (Upper Lift Cylinder) . . . . . . . . . . . . . . . . . . . 5-3
Cylinders With Dual Counterbalance Valve (Lower Lift, Telescope, and Slave Cylinders) . 5-4
5.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5 Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Upper (Main) Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Upper (Main) Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Lower Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Lower Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Upper Boom Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Upper Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.6 Lower Lift Cylinder Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
Main Relief at Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Upper Lift Down Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Lower Lift Down Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Swing Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Telescope In Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Platform Level Up Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Platform Level Down Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Steer Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.8 Brake/Steer Valve Hydraulic filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
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Using the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Help Descriptions and Fault Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Analyzer Diagnostics Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
System Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .7-3
7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
iv – JLG Lift – 3120772

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-2. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-3. Torque Chart (Metric Conversion) - (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-4. Torque Chart - (N, m) - (For Metric Class Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
3-1. Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-2. Main Disassembly Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-3. Main Disassembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-4. Output Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-5. Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-6. Input Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-7. Hub Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-8. Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-9. Hub Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-10. Hub Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-11. Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-12. Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-13. Drive Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-14. Speed Sensor Orientation. (E300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-15. Frame Mounted Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-16. Steering Components and Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-17. Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-18. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-19. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3-20. Swing Bearing Tolerance Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-21. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3-22. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-23. Seal Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-24. Notch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-25. Timing Mark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-26. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
3-27. Swing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
3-28. Rotary Actuator (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-29. Rotary Actuator (Cutaway View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3-30. Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
3-31. Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
3-32. Battery Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
3120772 – JLG Lift – v

LIST OF FIGURES

4-1. Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2. Tower Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-3. Location of wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-4. Jib - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-5. Jib - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-6. Platform Support Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-7. Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
5-1. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-2. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-3. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-5. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-6. Gar-Max Bearing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-7. Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-8. Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-9. Main Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-10. Tower Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5-11. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-12. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5-13. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5-14. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-15. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-16. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-17. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-18. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-19. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-20. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-21. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-22. Upper Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-23. Lower Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
5-24. Upper Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-25. Brake/Steer Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
5-26. Control Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
5-27. Main Valve Components - Prior to S/N 0300063313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
5-28. Main Valve Components - S/N 0300063313 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
5-29. HydraForce Cartridge Torque Value Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
vi – JLG Lift – 3120772

LIST OF FIGURES

6-1. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6-2. Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-3. Analyzer Flow Chart - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6-4. Analyzer Flow Chart - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
7-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
7-5. Connector Assembly Figure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-14. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-18. Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
7-19. Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
7-20. Electrical Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
7-21. Electrical Schematic - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
7-22. Hydraulic Schematic - 300A - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
7-23. Hydraulic Schematic - 300A - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
7-24. Hydraulic Schematic - 300AJ - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
7-25. Hydraulic Schematic - 300AJ - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
7-26. Hydraulic Schematic - 300AJP - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
7-27. Hydraulic Schematic - 300AJP - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
3120772 – JLG Lift – vii

LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Operating Specifications - E300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Operating Specifications - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Operating Specifications - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-9 Hydraulic Pump/Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-10 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-11 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-12 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-13 Pressure Settings - Prior to S/N 0300063313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-14 Pressure Settings - S/N 0300063313 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-15 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-16 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-17 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-18 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-19 Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-20 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-21 Mobil EAL 224H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-22 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-2 Drive Brake Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
5-1 Cylinder Head and Tapered Bushing Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-3 Pressure Settings - Prior to S/N 0300063313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
5-4 Pressure Settings - S/N 0300063313 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
6-1 Machine Setup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6-3 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6-4 JLG Control System Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6-5 Help Descriptions and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6-6 Diagnostics - Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21
6-7 System Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-8 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
viii – JLG Lift – 3120772

SECTION 1. SPECIFICATIONS
1.1 CAPACITIES Table 1-3. Operating Specifications - E300AJ

Table 1-1. Capacities
Capacity: Unrestricted: 500 lbs. (227 kg)
Hydraulic Oil Tank 3.0 gallons (11.35 liters) Maximum Travel Grade, stowed 25%
Hydraulic System (Including Tank) 4.0 gallons (15.14 liters) Position (Gradeability)
Maximum Travel Grade, stowed 5%

Torque Hub, Drive* 17 ounces (0.50 L)
Position (Side Slope)
*Torque hubs should be one half full of lubricant. Vertical Platform Height 30 ft. (9.14 m
Horizontal Platform Reach 20 ft. (6.1 m)

1.2 OPERATING SPECIFICATIONS (Up & Over)
Table 1-2. Operating Specifications - E300A Machine Width 4 ft. (1.22 m)
Capacity: Unrestricted: 500 lbs. (227 kg) Turning Radius (Outside) 10 ft. (3.05 m)
Maximum Travel Grade, stowed 25% Turning Radius (Inside) 5 ft. (1.52 m)
Position (Gradeability) see Figure 4-3.
Drive Speed (High Drive) 45-50 sec/ 200ft. (61 m)
Maximum Travel Grade, stowed 5% (Above Horz.) 55-68 sec/ 50 ft. (15.2 m)
Position (Side Slope) see Figure 4-3.
Gross Machine Weight 15,400 lbs. (6985 kg)
Vertical Platform Height 30 ft. (9.14 m)
Maximum System Voltage 48 VDC
Horizontal Platform Reach 20 ft. (6.1 m)
Maximum Main Relief Hyd. Pressure 2500 psi. (172.3 bars)
(Up & Over)
Machine Width 4 ft. (1.22 m) Table 1-4. Operating Specifications - E300AJP

Turning Radius (Outside) 10 ft. (3.05 m)
Capacity: Unrestricted: 500 lbs. (227 kg)
Turning Radius (Inside) 5 ft. (1.52 m)
Drive Speed (High Drive) 45-50 sec/ 200ft. (61 m) Position (Gradeability)
(Above Horz.) 55-68 sec/ 50 ft. (15.2 m)
Gross Machine Weight 14,300 lbs. (6,487 kg) Position (Side Slope)
Maximum System Voltage 48 VDC Vertical Platform Height 30 ft. (9.14 m
Maximum Main Relief Hyd. Pressure 2500 psi. (172.3 bars) Horizontal Platform Reach 20 ft. (6.1 m)
(Up & Over)
Machine Width 4 ft. (1.22 m)
Turning Radius (Outside) 10 ft. (3.05 m)
Turning Radius (Inside) 5 ft. (1.52 m)
Drive Speed (High Drive) 45-50 sec/ 200ft. (61 m)

(Above Horz.) 55-68 sec/ 50 ft. (15.2 m)
Gross Machine Weight 15,800 lbs. (7167 kg)
Maximum System Voltage 48 VDC
Maximum Main Relief Hyd. Pressure 3200 psi. (220.6 bars)
3120772 – JLG Lift – 1-1

1.3 BATTERY CHARGER 1.7 HYDRAULIC PUMP/ELECTRIC MOTOR

Table 1-5. Battery Charger
ASSEMBLY
Table 1-9. Hydraulic Pump/Electric Motor
Input 110 VAC,60 HZ
Motor 48 VDC, 2.14 H.P. @ 2700 rpm
Output 48 VDC (23 Amps)
Displacement 0.19 cu. in./rev. (3.12 cm3/rev.)
Batteries (8) 6 Volt, 370 AmpHour (20 hour rate)
Output 2.71 gpm (10,25 lpm) @ 2000 psi (137.9 Bar)
1.4 DRIVE SYSTEM

1.8 DIMENSIONAL DATA
Table 1-6. Drive System
Table 1-10. Dimensional Data
Drive Motor 48 VDC, 12.5 H.P. @ 3200 rpm.
continuous, rotation - reversible Turning Radius (Inside) 5 ft. (1.52 m.)
Drive Brake spring-applied, hydraulically Turning Radius (Outside) 10 ft. - 0 in. (3.05 m)
released
Machine Height (stowed) 6 ft., 7.0 in. (2.0 m.)
Machine Length (stowed)

1.5 TIRES E300A 17 ft.,2 in. (5.23 m.)
E300AJ/AJP 18 ft., (5.48 m)
Table 1-7. Tire Specifications
Up and Over Platform Height 13 ft.,1.0 in. (3.99 m.).
Size 7.5 x 12
Horizontal Reach Up and Over 20 ft. (6.1 m.).
Compound Non Marking Compound
Machine Width 4 ft., (1.22 m.)
Max. Tire Load 6000 lbs. (2722 kg)
Wheel Base 6 ft., 7.25 in. (2.01 m.)
Platform Height 30 ft., 0 in. (9.14 m.)

1.6 HYDRAULIC FILTER
Table 1-8. Hydraulic Filter
Type Return
Micron Rating 25 Micron
1-2 – JLG Lift – 3120772

1.9 FUNCTION SPEEDS 1.10 TORQUE SPECIFICATIONS

Table 1-11. Function Speeds Table 1-12. Torque Requirements
Speed Description Torque Value Interval Hours

Function in seconds (unless Bearing To Chassis (w/Loctite) 240 ft. lbs. 50/600*
otherwise noted)
(326 Nm)*
Travel Speed (Forward & Reverse) Bearing To Turntable (w/Loctite) 240 ft. lbs. 50/600*
High drive 3 mph (4.8 kmh) (326 Nm)*
(45-50 sec / 200 ft.)
Wheel Lugs (Dry) 170 ft.lb. 150
Travel Speed (Forward & Reverse) (230Nm)
boom above Horizontal 0.62 mph (1 kmh)
NOTE: *Check swing bearing bolts for security after first
(55-68 sec / 50ft.)
50 hours of operation and every 600 hours there-
Upper Lift Up 24-27 after.
Upper Lift Down 20-23
Boom Telescope Out

1.11 PRESSURE SETTINGS
E300A 17-20 Table 1-13. Pressure Settings - Prior to S/N 0300063313
E300AJ, AJP 12-15
Circuit PSI Bar
Boom Telescope In
E300A 17-20 Main Control Valve
E300AJ, AJP 12-15
Upper Lift Down Relief 1500 103
Lower Lift Up 17 - 20
Lower Lift Down Relief 1350 93
Lower Lift Down 17 - 20
Telescope In Relief (A/AJ) 2150 148
Swing - 360 Degrees 79 - 86
Telescope In Relief (AJP) 3000 207
Jib (300AJ)
Up 22 - 25 Platform Level Up Relief 1500 103
Down 22 - 25
Platform Level Down Relief 1500 103
Jib Swing (300AJP)*
Right 45- 55 Steer/Brake Valve
Left 45- 55
Steer Relief 2300 159
*Max 10% difference between left and right
Main Relief (A/AJ) 2500 172
Platform Rotate, Left and Right* 10-12
*Max. 15% difference between left and right Main Relief (AJP) 3200 221
3120772 – JLG Lift – 1-3

Table 1-14. Pressure Settings - S/N 0300063313 to 1.13 MAJOR COMPONENT WEIGHTS
Present
Circuit PSI Bar

SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF
Main Control Valve SAFELY SUPPORTING WEIGHT
Upper Lift Down Relief 550 38 Table 1-16. Major Component Weights
Lower Lift Down Relief 1700 117
COMPONENT LBS. KG.
Telescope Relief (A/AJ) 2150 148
Platform & Support & Rotator 215 97.5
Telescope Relief (AJP) 3000 207
Main Boom complete w/ Master & Slave 880 399.1
Platform Level Up Relief 3000 207 Cyl.
Platform Level Down Relief 1200 83 Telescope Cylinder 80 36.2
Steer/Brake Valve Lift Cylinder 103 46.7
Steer Relief 2300 159 Upright with Upper and Lower Arms 692 313.9
Main Relief (A/AJ) 2500 172 Tower Lift Cylinder 68 30.8
Main Relief (AJP) 3200 221 Turntable w/Cwt.,battery boxes, tank, etc. 7200 3266
Battery Box (includes batteries) 660 299.3

1.12 CYLINDER SPECIFICATIONS Chassis (includes non marking Tires) 5380 2440
NOTE: All dimensions are given in inches (in.), with the met- Counterweight (A/AJ) 5300 2404.1
ric equivalent, millimeters (mm) given in parenthe- Counterweight (AJP) 5900 2676.2
ses.
Machine Complete - A 14,500 6577
Table 1-15. Cylinder Specifications Machine Complete - AJ 15,400 6985
Machine Complete - AJP 15,800 7167
DESCRIPTION BORE STROKE ROD DIA.
Swing Jib 320 145
Upper Lift Cylinder 3.5 in. (8.9 cm) 25.9 in.(65.8 cm) 2.0 in.(5.1 cm)
Lower Lift Cylinder 3.0 in.(7.6. cm) 28.5 in.(72.4 cm) 1.5 in.(3.8 cm)
Telescope Cylinder 2.0 in.(5.1 cm) 38.5 in.(98.0 cm) 1.25 in.(3.2 cm)
Master Cylinder 3.0 in.(7.6 cm) 11.5 in.(29.1 cm) 1.25 in.(3.2 cm)
Slave Cylinder 3.0 in.(7.6 cm) 11.5 in.(29.1 cm) 1.25 in.(3.2 cm)
Steer Cylinder 2.5 in.(6.3 cm) 7.0 in.(17.8 cm) 1.5 in.(3.8 cm)
1-4 – JLG Lift – 3120772

Critical Stability Weights 1.15 HYDRAULIC OIL

Table 1-18. Hydraulic Oil
Hydraulic System
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS S.A.E. Viscosity
Operating
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BAT- Grade
Temperature Range
TERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN
ANY WAY TO AFFECT STABILITY. +0° to + 180° F 10W
(-18° to +83° C)
Table 1-17. Critical Stability Weights +0° to + 210° F 10W-20, 10W30
(-18° to +99° C)
Components LBS. KG. +50° to + 210° F 20W-20
(+10° to +99° C
Counterweight 5300 2404.1
Tire and Wheel 120 54.4 NOTE: Hydraulic oils require anti-wear qualities at least API
Service Classification GL-3, and sufficient chemical
Tire and Wheel (CSA) 262 119 stability for mobile hydraulic system service.
Platform 135 61.2 NOTE: Machines may be equipped with Mobil EAL224H
biodegradable and non-toxic hydraulic oil. This is
Battery (each) 110 50
vegetable oil based and possesses the same anti-
wear and rust protection characteristics as mineral
oils, but will not adversely affect the ground water or
1.14 SERIAL NUMBER LOCATIONS the environment when spilled or leaked in small
For machines identification, a serial number plate is amounts. Mobil EAL224H has a viscosity of 34 cSt
affixed to the turntable, on the front of the left battery box at 40° C. and viscosity index of 213. The operating
support plate. If the serial number plate is damaged or temperature range of this oil is -18° C. to +83° C.
missing, the machine serial number is stamped on the top
right front of the frame. NOTE: Aside from JLG recommendations, it is not advis-
able to mix oils of different brands or types, as they
may not contain the same required additives or be
of comparable viscosities. If use of hydraulic oil
other than Mobil DTE 11M is desired, contact JLG
Industries for proper recommendations.
3120772 – JLG Lift – 1-5

Table 1-19. Mobil DTE 11M Specs Table 1-21. Mobil EAL 224H Specs
ISO Viscosity Grade #15 Type Synthetic Biodegradable

Gravity API 31.9 ISO Viscosity Grade 32/46
Pour Point, Max -40°F (-40°C) Specific Gravity .922
Flash Point, Min. 330°F (166°C) Pour Point, Max -25°F (-32°C)
Viscosity Flash Point, Min. 428°F (220°C)
at 40° C 15 cSt Operating Temp. 0 to 180°F (-17 to 162°C)
at 100° C 4.1 cSt Weight 7.64 lb. per gal.
at 100° F 80 SUS (0.9 kg per liter)
at 210° F 43 SUS Viscosity
cp at -30° F 3.200 at 40° C 37 cSt
Viscosity Index 140 at 100° C 8.4 cSt

Viscosity Index 213
NOTE: Must be stored above 32°F (0°C)
NOTE: Machines Manufactured before S/N 03000046376
were filled with Mobilfluid 424 hydraulic oil. If desired
to change to Mobil DTE 11M hydraulic oil, the tele-
scope seals are recommended to be changed.
These are included in (JLG) kit P/N 8457399. Also
included in the kit, is a decal to be located on the
hydraulic tank to identify Mobil DTE 11M oil in use.
Table 1-20. Mobilfluid 424 Specs
SAE Grade 10W30

Gravity, API 29.0
Density, Lb/Gal. 60°F 7.35
Pour Point, Max -46°F (-43°C)
Flash Point, Min. 442°F (228°C)
Viscosity
Brookfield, cP at -18°C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
1-6 – JLG Lift – 3120772

8
8
8
8
3
4
7
1,2
5 6
Figure 1-1. Operator Maintenance & Lubrication Diagram
1.16 LUBRICATION NOTE: It is recommended as a good practice to replace all

filters at the same time.
NOTE: The following numbers correspond to those in Fig-
ure 1-1., Operator Maintenance & Lubrication Dia-
gram.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION
Table 1-22. Lubrication Specifications. UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-
SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON-
KEY SPECIFICATIONS MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
MPG Multipurpose Grease having a minimum dripping point of
350 degrees F. Excellent water resistance and adhesive
qualities; and being of extreme pressure type (Timken OK 1. Swing Bearing
40 pounds minimum).
Lube Point(s) - 2 Grease Fittings
EPGL Extreme Pressure Gear Lube (oil) meeting API Service Capacity - A/R
Classification GL-5 or Mil-Spec Mil-L-2105. Lube - MPG
HO Hydraulic Oil. Mobil DTE-11M Interval - Every 3 months or 150 hrs of operation
OG* Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Com-
pound. (JLG Part No. 3020027)
BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA
460.
LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG
Part No. 3020022)
EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-
2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-
2104C.
*MPG may be substituted for these lubricants, if necessary,
but service intervals will be reduced.
3120772 – JLG Lift – 1-7

2. Swing Bearing/Worm Gear Teeth 5. Wheel Drive Hub
Lube Point(s) - 2 Grease Fittings Lube Point(s) - Level/Fill Plug

Capacity - Spray On Capacity - 17 oz. (1/2 Full)
Lube - Mobiltac375NC Lube - EPGL
Interval - A/R Interval - Check level every 3 months or 150 hrs of
Comments - If necessary install grease fittings into operation; change every 2 years or 1200 hours of
worm gear housing and grease bearings. operation
6. Wheel Bearings
DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS

WILL RESULT IN DAMAGE TO OUTER SEAL IN HOUSING.
3. Hydraulic Tank
Lube Point(s) - Fill Cap Lube Point(s) - Repack

Capacity - 4 Gal. (15.1 L) Capacity - A/R
Lube - HO Lube - MPG
Interval - Check Level daily; Change every 2 years or Interval - Every 2 years or 1200 hours of operation
1200 hours of operation. 7. Spindles/Bushing
Comments - On new machines, those recently over-
hauled, or after changing hydraulic oil, operate all Capacity - A/R
systems a minimum of two complete cycles and Lube - Lithium Lubricant
recheck oil level in reservoir. Interval - Every 2 years or 1200 hours of operation
Comments - At Spindle/Bushing Replacement; Coat
4. Hydraulic Return Filter I.D. of bushings prior to installing king pins.
Interval - Change after first 50 hrs. and every 6 8. Boom Pivot Pins/Bushing
months or 300 hrs. thereafter.
Comments - Under certain conditions, it may be Capacity - A/R
necessary to replace the hydraulic filter on a more Lube - Lithium Lubricant
frequent basis. A common symptom of a dirty filter is Interval - Every 2 years or 1200 hours of operation
sluggishness experienced in hydraulic functions. Comments - At boom pivot pins/bushing replace-
ment; Coat I.D. of bushings prior to installing pivot
pins.
1-8 – JLG Lift – 3120772

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
3120772
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
STRESS LOCTITE LOCTITE
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB
40 0.00604 380 8 6 — — 540 12 9 — — — — —
4 0.1120
48 0.00661 420 9 7 — — 600 13 10 — — — — —
32 0.00909 580 16 12 — — 820 23 17 — — — — —
6 0.1380
40 0.01015 610 18 13 — — 920 25 19 — — — — —
32 0.01400 900 30 22 — — 1260 41 31 — — — — —
8 0.1640
36 0.01474 940 31 23 — — 1320 43 32 — — — — —
24 0.01750 1120 43 32 — — 1580 60 45 — — — — —
10 0.1900
32 0.02000 1285 49 36 — — 1800 68 51 — — — — —
20 0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168
1/4 0.2500
28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178
IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB
18 0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28
5/16 0.3125
24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30
16 0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50
3/8 0.3750
24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55
14 0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77
7/16 0.4375
20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82
– JLG Lift –
13 0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120
1/2 0.5000
20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127
12 0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170
9/16 0.5625
18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182
11 0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231
5/8 0.6250
18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242
10 0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400
3/4 0.7500
16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440
9 0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645
7/8 0.8750
14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700
8 0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950
1 1.0000
12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000
7 0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365
Figure 1-2. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners)

1-1/8 1.1250
12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520
7 0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925
1-1/4 1.2500
12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070
6 1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550
1-3/8 1.3750
12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685
6 1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345
1-1/2 1.5000
12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600
Note: These torque values do not apply to cadmium plated fasteners.

1-9
1-10
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
40 0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —
4 0.1120
48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —
32 0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —
6 0.1380
40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — —
32 0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —
8 0.1640
36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — —
24 0.01750 1120 5 3.6 — — 1580 7 5 — — — — —
10 0.1900
32 0.02000 1285 6 4 — — 1800 8 6 — — — — —
20 0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19
1/4 0.2500
28 0.0364 2320 14 10 — 15 3280 19 14 — 21 3640 19 20
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
18 0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38
5/16 0.3125
24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41
16 0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68
3/8 0.3750
24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75
14 0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104
7/16 0.4375
20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111
13 0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163
1/2 0.5000
20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172
– JLG Lift –
12 0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230
9/16 0.5625
18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247
11 0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313
5/8 0.6250
18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328
10 0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542
3/4 0.7500
16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597
9 0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874
7/8 0.8750
14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949
8 0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288
1 1.0000
12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356
7 0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851
1-1/8 1.1250
12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061
7 0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610
1-1/4 1.2500
12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807
Figure 1-3. Torque Chart (Metric Conversion) - (For ASTM Fasteners)

6 1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457
1-3/8 1.3750
12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640
6 1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535
1-1/2 1.5000
12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881
3120772
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

CLASS 8.8 METRIC BOLTS & CLASS 10.9 METRIC BOLTS &
CLASS 8 METRIC NUTS CLASS 10 METRIC NUTS
TORQUE TORQUE
TENSILE
CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE
SIZE PITCH LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR
AREA 262 262
263 271 263 271
sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m
3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1
3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3
4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8
5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7
6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17
7 1 28.9 12.6 18 13 16 19 18 25 19 20 28
8 1.25 36.6 15.9 25 19 23 28 22.8 37 27 29 40
10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79
12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139
14 2 115 50.0 140 105 126 154 71.6 200 150 160 220
16 2 157 68.3 219 164 197 241 97.8 313 235 250 344
18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473
20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671
22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915
24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170
27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690
30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310
33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860
36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020
42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440
METRIC CLASS 8.8 METRIC CLASS 10.9
Figure 1-4. Torque Chart - (N, m) - (For Metric Class Fasteners).
3120772 – JLG Lift – 1-11

NOTES:
1-12 – JLG Lift – 3120772

SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
General areas of this manual for servicing and maintenance proce-
dures.
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
Annual Machine Inspection
operating condition. For maximum service life and safe The Annual Machine Inspection must be performed by a
operation, ensure that all the necessary inspections and Factory-Certified Service Technician on an annual basis,
maintenance have been completed before placing the no later than thirteen (13) months from the date of the
machine into service. prior Annual Machine Inspection. JLG Industries, Inc. rec-
ognizes a Factory-Certified Service Technician as a per-
Preparation, Inspection, and Maintenance son who has successfully completed the JLG Service
Training School for the subject JLG product model. Refer-
It is important to establish and conform to a comprehen-
ence the machine Service and Maintenance Manual and
sive inspection and preventive maintenance program. The
appropriate JLG inspection form for performance of this
following table outlines the periodic machine inspections
inspection.
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for fur- Reference the JLG Annual Machine Inspection Form and
ther requirements for aerial work platforms. The frequency the Inspection and Preventative Maintenance Schedule for
of inspections and maintenance must be increased as items requiring inspection during the performance of this
environment, severity and frequency of usage requires. inspection. Reference the appropriate areas of this man-
ual for servicing and maintenance procedures.
Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is
It is the User’s or Operator’s primary responsibility to per- important that JLG Industries, Inc. has updated ownership
form a Pre-Start Inspection of the machine prior to use information for each machine. When performing each
daily or at each change of operator. Reference the Opera- Annual Machine Inspection, notify JLG Industries, Inc. of
tor’s and Safety Manual for completion procedures for the the current machine ownership.
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to per- Preventative Maintenance
forming the Pre-Start Inspection.
In conjunction with the specified inspections, mainte-
nance shall be performed by a qualified JLG equipment
Pre-Delivery Inspection and Frequent mechanic. JLG Industries, Inc. recognizes a qualified JLG
Inspection equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, train-
The Pre-Delivery Inspection and Frequent Inspection shall
ing, or experience, has successfully demonstrated the
be performed by a qualified JLG equipment mechanic.
ability and proficiency to service, repair, and maintain the
JLG Industries, Inc. recognizes a qualified JLG equipment
subject JLG product model.
mechanic as a person who, by possession of a recog-
nized degree, certificate, extensive knowledge, training, or Reference the Preventative Maintenance Schedule and
experience, has successfully demonstrated the ability and the appropriate areas of this manual for servicing and
proficiency to service, repair, and maintain the subject maintenance procedures. The frequency of service and
JLG product model. maintenance must be increased as environment, severity
and frequency of usage requires.
The Pre-Delivery Inspection and Frequent Inspection pro-
cedures are performed in the same manner, but at differ-
ent times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser-
vice for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
increased as environment, severity and frequency of
usage requires.
3120772 – JLG Lift – 2-1

SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operator and Safety Manual
At each Operator change.
Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance
Inspection rental delivery. Mechanic Manual and applicable JLG
inspection form.
Frequent Inspection In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance
ever comes first; or Mechanic Manual and applicable JLG
Out of service for a period of more than 3 inspection form.
months; or
Purchased used.
Annual Machine Annually, no later than 13 months from the Owner, Dealer, or User Factory-Certified Service and Maintenance
Inspection date of the prior inspection. Service Technician Manual and applicable JLG
inspection form.
Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance Maintenance Manual. Mechanic Manual
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo-
General nent is disconnected, cap or cover all openings to
The following information is provided to assist you in the prevent entry of foreign matter.
use and application of servicing and maintenance proce- 3. Clean and inspect all parts during servicing or main-
dures contained in this book. tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
Safety and Workmanship clean. Be sure all parts are clean before they are
installed. New parts should remain in their contain-
Your safety, and that of others, is the first consideration ers until they are ready to be used.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy Components Removal and Installation
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising 1. Use adjustable lifting devices, whenever possible, if
a portion of the equipment, ensure that adequate support mechanical assistance is required. All slings (chains,
is provided. cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
Cleanliness lifted.
1. The most important single item in preserving the 2. Should it be necessary to remove a component on
long service life of a machine is to keep dirt and for- an angle, keep in mind that the capacity of an eye-
eign materials out of the vital components. Precau- bolt or similar bracket lessens, as the angle between
tions have been taken to safeguard against this. the supporting structure and the component
Shields, covers, seals, and filters are provided to becomes less than 90 degrees.
keep air, fuel, and oil supplies clean; however, these 3. If a part resists removal, check to see whether all
items must be maintained on a scheduled basis in nuts, bolts, cables, brackets, wiring, etc., have been
order to function properly. removed and that no adjacent parts are interfering.
2-2 – JLG Lift – 3120772

SECTION 2 - GENERAL
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within
the text, standard torque values should be used on
When disassembling or reassembling a component, com- heat-treated bolts, studs, and steel nuts, in accor-
plete the procedural steps in sequence. Do not partially dance with recommended shop practices. (See
disassemble or assemble one part, then start on another. Torque Chart Section 1.)
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than Hydraulic Lines and Electrical Wiring
those recommended, without obtaining proper approval.
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
Pressure-Fit Parts them from the unit. This will assure that they are correctly
When assembling pressure-fit parts, use an anti-seize or reinstalled.
molybdenum disulfide base compound to lubricate the
mating surface. Hydraulic System
1. Keep the system clean. If evidence of metal or rub-
Bearings ber particles are found in the hydraulic system, drain
and flush the entire system.
1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable 2. Disassemble and reassemble parts on clean work
cleaning solvent and allow to drip dry. Compressed surface. Clean all metal parts with non-flammable
air can be used but do not spin the bearing. cleaning solvent. Lubricate components, as
required, to aid assembly.
2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned. Lubrication
3. If bearing is found to be serviceable, apply a light
Service applicable components with the amount, type,
coat of oil and wrap it in clean (waxed) paper. Do not
and grade of lubricant recommended in this manual, at
unwrap reusable or new bearings until they are
the specified intervals. When recommended lubricants are
ready to install.
not available, consult your local supplier for an equivalent
4. Lubricate new or used serviceable bearings before that meets or exceeds the specifications listed.
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear- Battery
ing is to be installed on a shaft, apply pressure to the
inner race. Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
Gaskets cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a Lubrication and Servicing
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as Components and assemblies requiring lubrication and
blank gaskets can cause serious system damage. servicing are shown in the Lubrication Chart in Section 1.
Bolt Usage and Torque Application

1. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications of the original, or one which is
equivalent.
3120772 – JLG Lift – 2-3

SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION Changing Hydraulic Oil

1. Filter elements must be changed after the first 50
Hydraulic System hours of operation and every 300 hours thereafter. If
1. The primary enemy of a hydraulic system is contam- it is necessary to change the oil, use only those oils
ination. Contaminants enter the system by various meeting or exceeding the specifications appearing
means, e.g., using inadequate hydraulic oil, allowing in this manual. If unable to obtain the same type of
moisture, grease, filings, sealing components, sand, oil supplied with the machine, consult local supplier
etc., to enter when performing maintenance, or by for assistance in selecting the proper equivalent.
permitting the pump to cavitate due to insufficient Avoid mixing petroleum and synthetic base oils. JLG
system warm-up or leaks in the pump supply (suc- Industries recommends changing the hydraulic oil
tion) lines. annually.
2. The design and manufacturing tolerances of the 2. Use every precaution to keep the hydraulic oil clean.
component working parts are very close, therefore, If the oil must be poured from the original container
even the smallest amount of dirt or foreign matter into another, be sure to clean all possible contami-
entering a system can cause wear or damage to the nants from the service container. Always clean the
components and generally results in faulty opera- mesh element of the filter and replace the cartridge
tion. Every precaution must be taken to keep any time the system oil is changed.
hydraulic oil clean, including reserve oil in storage. 3. While the unit is shut down, a good preventive main-
Hydraulic system filters should be checked, tenance measure is to make a thorough inspection
cleaned, and/or replaced as necessary, at the speci- of all hydraulic components, lines, fittings, etc., as
fied intervals required in the Lubrication Chart in well as a functional check of each system, before
Section 1. Always examine filters for evidence of placing the machine back in service.
metal particles.
3. Cloudy oils indicate a high moisture content which Lubrication Specifications
permits organic growth, resulting in oxidation or cor-
Specified lubricants, as recommended by the component
rosion. If this condition occurs, the system must be
manufacturers, are always the best choice, however,
drained, flushed, and refilled with clean oil.
multi-purpose greases usually have the qualities which
4. It is not advisable to mix oils of different brands or meet a variety of single purpose grease requirements.
types, as they may not contain the same required Should any question arise, regarding the use of greases in
additives or be of comparable viscosities. Good maintenance stock, consult your local supplier for evalua-
grade mineral oils, with viscosities suited to the tion. Refer to Section 1 for an explanation of the lubricant
ambient temperatures in which the machine is oper- key designations appearing in the Lubrication Chart.
ating, are recommended for use.
NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing compo-
nents.
Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
2. JLG recommends Mobil DTE 11M Hydraulic Oil,
which has an SAE viscosity of 10W and a viscosity
index of 140. A decal, located on the hydraulic tank,
will identify this oil.
NOTE: Start-up of hydraulic system with oil temperatures

below -15 degrees F. is not recommended. If it is
necessary to start the system in a sub-zero environ-
ment, it will be necessary to heat the oil with a low
density 100VAC heater to a minimum temperature of
-15 degrees F. (-26 degrees C.)
NOTE: Mobil DTE 11M hydraulic oil may purchased from

JLG in 4 Gal. containers. (P/N 2300028)
2-4 – JLG Lift – 3120772

SECTION 2 - GENERAL
2.4 CYLINDER DRIFT TEST 2.5 PINS AND COMPOSITE BEARING

Maximum acceptable cylinder drift is to be measured REPAIR GUIDELINES
using the following methods.
Filament wound bearings.
Platform Drift 1. Pinned joints should be disassembled and

inspected if the following occurs:
Measure the drift of the platform to the ground. Lower
booms (if equipped) slightly elevated, main boom fully a. Excessive sloppiness in joints.
extended with the rated load in the platform and power off. b. Noise originating from the joint during operation.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes. 2. Filament wound bearings should be replaced if any
If the machine does not pass this test, proceed with the of the following is observed:
following.
a. Frayed or separated fibers on the liner surface.
Cylinder Drift b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their hous-
ing.
Table 2-2. Cylinder Drift d. Debris embedded in liner surface.
Max. Acceptable Drift 3. Pins should be replaced if any of the following is

Cylinder Bore Diameter observed (pin should be properly cleaned prior to
in 10 Minutes
inspection):
inches mm inches mm
a. Detectable wear in the bearing area.
3 76.2 0.026 0.66
b. Flaking, pealing, scoring, or scratches on the pin
3.5 89 0.019 0.48 surface.
4 101.6 0.015 0.38 c. Rusting of the pin in the bearing area.
5 127 0.009 0.22 4. Re-assembly of pinned joints using filament wound
6 152.4 0.006 0.15 bearings.
7 177.8 0.005 0.13 a. Housing should be blown out to remove all dirt
8 203.2 0.0038 0.10 and debris...bearings and bearing housings
9 228.6 0.0030 0.08 must be free of all contamination.
b. Bearing / pins should be cleaned with a solvent
Drift is to be measured at the cylinder rod with a calibrated to remove all grease and oil...filament wound
dial indicator. The cylinder oil must be at ambient temper- bearing are a dry joint and should not be lubri-
ature and temperature stabilized. cated unless otherwise instructed (i.e. sheave
pins).
The cylinder must have the normal load, which is the nor- c. Pins should be inspected to ensure it is free of
mal platform load applied. burrs, nicks, and scratches which would dam-
age the bearing during installation and opera-
If the cylinder passes this test, it is acceptable. tion.
NOTE: This information is based on 6 drops per minute cyl-
inder leakage.
3120772 – JLG Lift – 2-5

SECTION 2 - GENERAL
2.6 WELDING ON JLG EQUIPMENT Do NOT Do the Following When Welding on

NOTE: This instruction applies to repairs, or modifications to JLG Equipment
the machine and to welding performed from the • Ground on frame and weld on any other area than the
machine on an external structure, or component, chassis.
• Ground on turntable and weld on any other area than
Do the Following When Welding on JLG the turntable.
Equipment • Ground on the platform/support and weld on any other
• Disconnect the battery. area than the platform/support.
• Disconnect the moment pin connection (where fitted) • Ground on a specific boom section and weld on any
other area than that specific boom section.
• Ground only to structure being welded.
• Allow pins, wear pads, wire ropes, bearings, gearing,
seals, valves, electrical wiring, or hoses to be between
the grounding position and the welded area.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY

RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
2-6 – JLG Lift – 3120772

SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Weekly Monthly Pre-Delivery2 Annual4

Pre-Start1 Preventive Preventive or Frequent3
Every 2
(Yearly) Years
Inspection Maintenance Maintenance Inspection Inspection
Boom Assembly 9
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Platform Assembly 9
Platform 1,2 1,2
Railing 1,2 1 1,2
Gate 5 1 1,5
Floor 1,2 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 2 1,2,10 1,2,10
Turntable Assembly 9
Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly 9
Tires 1 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 1 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components
Drive Motors
Drive Hubs 11 11
Functions/Controls 9
Platform Controls 5 5 6 6
3120772 – JLG Lift – 2-7

SECTION 2 - GENERAL
INTERVAL

Every 2
(Yearly) Years
Ground Controls 5 5 6 6
Function Control Locks, Guards, or Detents 1,5 1,5 5 5
Footswitch 1,5 5 5
Emergency Stop Switches (Ground & Platform) 5 5 5
Function Limit or Cutout Switch Systems 5 5 5
Capacity Indicator 5
Drive Brakes 5
Swing Brakes 5
Boom Synchronization/Sequencing Systems 5
Manual Descent or Auxiliary Power 5 5
Power System 9
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 11 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 5 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5
Hydraulic/Electric System 9
Hydraulic Pumps 1,9 1,2,9
Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2
Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 11 7,11 7,11
Electrical Connections 1 20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operation and Safety Manuals in Storage Box 21 21 21
ANSI and EMI Manuals/Handbooks Installed 21
Capacity Decals Installed, Secure, Legible 21 21 21
All Decals/Placards Installed, Secure, Legible 21 21 21
2-8 – JLG Lift – 3120772

SECTION 2 - GENERAL
INTERVAL

Every 2
(Yearly) Years
Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
3120772 – JLG Lift – 2-9

SECTION 2 - GENERAL
NOTES:
2-10 – JLG Lift – 3120772

SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES AND WHEELS 2. Tighten nuts in the following sequence.
Tire Wear and Damage

Inspect tires periodically for wear or damage. Tires with
worn edges or distorted profiles require replacement.
Tires with significant damage in the tread area or side wall,
require immediate evaluation before replacing the
machine into service.
Wheel and Tire Replacement

Replacement wheels must have the same diameter and
profile as the original. Replacement tires must be the
same size and rating as the tire being replaced.
Wheel Installation
3. The tightening of the nuts should be done in stages.
It is extremely important to apply and maintain proper
wheel mounting torque. Following the recommended sequence, tighten nuts
per wheel torque.
Table 3-1. Wheel Torque Chart

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE
PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, TORQUE SEQUENCE
AND POSSIBLE SEPARATION OF WHEEL FROM THE AXLE. BE 1st Stage 2nd Stage 3rd Stage
SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE 40 ft lbs (55 Nm) 95 ft lbs (130 Nm) 170 ft lbs (230 Nm)
OF THE WHEEL.
Tighten the lug nuts to the proper torque to prevent 4. Wheel nuts should be torqued after first 50 hours of
wheels from coming loose. Use a torque wrench to operation and after each wheel removal. Check the
tighten the fasteners. If you do not have a torque torque after the first 10 miles, 25 miles, and again at
wrench, tighten the fasteners with a lug wrench, then 50 miles. Check periodically thereafter.
immediately have a service garage or dealer tighten
the lug nuts to the proper torque. Over-tightening will
result in breaking the studs or permanently deforming
the mounting stud holes in the wheels. The proper pro-
cedure for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
3120772 – JLG Lift – 3-1

3.2 DRIVE HUB PART NO. 2780236 changing the sun gear shaft (43) along with this set
of planets.
The final drive consists of two planetary stages with an
integrated disconnect mechanism. Each stage incorpo- 18. The second stage planetary bearings (11) must be
rates a set of matched planetary gears, which provide an replaced in sets of four pieces.
equal load distribution. All torque transmitting compo- 19. The second stage planetary gears (1) must be
nents are made of forged quenched and tempered high- changed as a complete set of four and JLG recom-
alloy steels. External gears are carburized. Precision roller mends changing the sun gear (3) along with this set
bearings support the sprocket or wheel loads. A shaft seal of planets.
protects the unit against contamination.
Disassembly of Cover
Disassembly
1. Loosen and remove hex head bolts (53) to remove
1. Position drive so that one of the fill holes is at the cover (51).
bottom of the end cover and drain the oil.
2. Remove shaft rod (56) and “o” ring (54).
2. Remove all bolts holding the motor and Remove
motor from drive. 3. Remove sleeve (52).
3. Compress the disc (59) using a simple fixture or Disassembly of the first stage planetary
other suitable device.
assembly (7)
4. Remove snap ring (66) and release pressure on disc
until loose. Remove tool and disc. 1. Push sun gear shaft (43) out of the first stage.
5. Remove the spring (55) from the input shaft (44). 2. Remove snap rings (14).
6. Turn unit so that cover (8) is in the up position. 3. Press planet pins (5) out of the planet gears (2).
7. Remove the screw plugs (22) and seal rings (21). 4. Pull cylindrical roller bearing (10) out of the planet
gears (2).
8. Remove snap rings (34), and remove the cover unit
(8) from drive. 5. Remove snap ring (16) from sun gear (3) and
Remove planet carrier (7) from sun gear (3).
9. Remove “o” ring (33).
6. Remove thrust washer (49).
10. Remove the first stage planetary assembly (7).
11. Remove hex bolts (23). Disassembly of second stage planet gears
12. Remove ring gear (30) and “o” ring (19). (1)
13. Remove snap rings (15). Press cylindrical roller bearings out of planet gears (1).
14. Pull off planet gears (1) together with cylindrical Assembly of first stage planetary assembly
roller bearings (11) from spindle (60).
(7)
NOTE: Further disassembly of the hub is discouraged. rein-
stallation of the shaft nut (4) requires a special tool 1. Pre-freeze planet pins (5) and install into planet car-
and a torque of 626 ft./ lbs. (876 Nm) for proper reas- rier (7).
sembly. These components Will Fail if not properly
2. Install planet carrier (7) together with planet pins (5)
reassembled.
on sun gear (3), and install snap ring (16).
15. Inspect the planetary stage assemblies as complete
3. Pre-heat thrust washer (49) and Install onto sun gear
units. Thoroughly clean and check both the gearing
shaft (43).
and the bearings for damage and apply new oil. If
the gears or bearings need replacing, they must be 4. Put sun gear shaft (43) into sun gear (3).
replaced as complete sets.
5. Pre-heat stay rings (17) and install onto planet pins
16. The first stage planetary gears (2) must be changed (5).
in sets of three pieces.
6. Pre-heat cylindrical roller bearings (10) and install
17. The first stage planetary gears (2) must be changed onto planet pins (5) and fix bearings with snap rings
as a complete set of three and JLG recommends (14).
3-2 – JLG Lift – 3120772

Assembly of end cover unit (8) Initial Start-up And After Repairs
Before operating the machine, make sure that the drive is
1. Press sleeve (52) into cover (8). filled with clean oil, approximately 0.2 US gallons(.8 L). An
accurate oil level is determined by the oil level plug, which
2. Install “o” ring (54) into groove of cover (8).
should be removed before oil fill.
3. Install shift rod (56) into cover (8).
With the gear case filled to their proper levels, start the
4. Install the cover (51) into cover (8) and fix cover (51) machine and allow sufficient time for run-in at moder-
with hex bolts (53). Tighten bolts with torque wrench ate pressure and speed before running at full speed.
to 6.3 ft. lbs. (8.5 Nm). After 4 hours of operation, recheck oil level.Mainte-
nance
Final Assembly
Daily: - Check for oil leakage
1. Install thrust washer (29) in spindle (60). Weekly: - Check oil level
2. Install “o” ring (19) into groove of support ring (6). Monthly: - Check mounting bolt torque
3. Install planet gears (1) onto planet pins which are Oil Change Interval-Gear Drive
part of spindle (60).
1. Perform the first oil change after approximately 150
4. Install snap rings (15) on planet pins of spindle (60) hours.
in order to fix the planet gears (1).
2. Subsequent changes, every 1500 hours or annually,
5. Put ring gear (30) onto support ring (6) and fix ring whichever occurs first.
gear (30) with hex head bolts (23). Tighten bolts with
torque wrench to 15.5 ft. lbs.(21.1 Nm). NOTE: Flush the drive before filling with new oil.
6. Insert the first stage planetary assembly (7) into

drive.
7. Install “o” ring (33) in groove of ring gear (30).
8. Install end the cover unit (8) on shoulder ring gear

(30) and fix with snap ring (34).
9. Install seal rings (21) and screw plugs (22).
10. Before installation of motor, CHECK THAT THERE IS

1-2mm OF CLEARANCE BETWEEN THE MOTOR
SPLINE SHAFT SHOULDER AND THE COUPLER
(62).
11. Install the motor and reconnect hydraulic lines.
12. Roll motor so that one fill plug is at 12 o’clock posi-

tion, and the other is at 3 o’clock. Fill to bottom of 3
o’ clock plug with gear oil. reinstall plugs
3120772 – JLG Lift – 3-3

Figure 3-1. Drive Hub
3-4 – JLG Lift – 3120772

3.3 DRIVE HUB (S/N 115723 TO PRESENT) 5. Using the same sequence, crisscross around the
bolt circle and apply an equal torque to the remain-
ing bolts.
Roll and Leak Testing
Torque-Hub units should always be roll and leak tested
before disassembly and after assembly to make sure
that the unit’s gears, bearings and seals are working
properly. The following information briefly outlines what
to look for when performing these tests.
THE ROLL TEST
The purpose of the roll test is to determine if the unit’s

gears are rotating freely and properly. You should be
able to rotate the gears in your unit by applying con-
stant force to the roll checker. If you feel more drag in
the gears only at certain points, then the gears are not
rolling freely and should be examined for improper
installation or defects. Some gear packages roll with
more difficulty than others. Do not be concerned if the
gears in your unit seem to roll hard as long as they roll
with consistency.
THE LEAK TEST (MAIN UNIT)
The purpose of a leak test is to make sure the unit is air

tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to Main Disassembly
fall after the unit has been pressurized and allowed to
1. Perform Roll Check and Leak Check if applicable
equalize. Leaks will most likely occur at the pipe plugs,
prior to disassembling the unit.
the main seal or wherever o-rings or gaskets are
located. The exact location of a leak can usually be 2. Drain oil from unit. Note the condition and volume of
detected by brushing a soap and water solution the oil.
around the main seal and where the o-rings or gaskets
3. Remove Coupling (7) from Spindle End first.
meet on the exterior of the unit, then checking for air
bubbles. If a leak is detected in a seal, o-ring or gasket, 4. Remove Retaining Ring (6G) by prying the open end
the part must be replaced, and the unit rechecked. of Retaining Ring out of the groove in the Ring Gear
Leak test at 10 psi for 20 minutes. (1F) with a screwdriver, then grasp the loose end
with pliers and pull the Retaining Ring completely
Tightening and Torquing Bolts out of the groove.
5. Remove the Cover Subassembly (6) from the unit.
If an air impact wrench is used to tighten bolts, extreme
The unit can be carefully pressurized with air to pop
care should be taken to ensure that the bolts are not
the cover out of the unit. Washer (2) may have to be
tightened beyond their specified torque.
removed separately because of the loose attach-
The following steps describe how to tighten and torque ment.
bolts or socket head cap screws in a bolt circle. 6. Remove the First Stage Sun Gear (10) if applicable.
1. Tighten (but do not torque) bolt "A" until snug. NOTE: On units with ratios greater than 36:1 numerically,
there will not be a separate First Stage Sun Gear
2. Go to the opposite side of the bolt circle and tighten (10), as the gear teeth will be integral to the Input
bolt "B" until equally snug. Shaft (9).
3. Crisscross around the bolt circle and tighten remain- 7. Remove the Input Carrier Sub-assembly (3). Contin-
ing bolts. ued on next page.
8. Remove the Second Stage Sun Gear (11).
4. Now use a torque wrench to apply the specified
torque to bolt "A". 9. Remove the Input Shaft (9).
3120772 – JLG Lift – 3-5

NOTE: On units with a ratio 48:1, the Sun Gear (11) and the 12. Lift the Ring Gear (1F) off of the Housing (1G).
Input Shaft (9) will need to be removed together.
13. Remove the O-ring (18) from between the Housing
10. Remove the Output Stage Carrier Sub-assembly (4) (1G) and the Ring Gear (1F).
11. Loosen and remove the three Flat Head Bolts (19)
that retain the Ring Gear (1F) to the Housing (1G).
1F. Ring Gear 7. Coupling

1G. Housing 9. Input Shaft
2. Washer 10. First Stage Sun Gear
3. Input Carrier Subassembly 11. Second Stage Sun Gear
4. Output Carrier Subassembly 15. I.D. Plate
6. Cover Assembly 18. O-ring
6G. Retaining Ring 19. Flat Head Bolts
Figure 3-2. Main Disassembly Drawing 1
3-6 – JLG Lift – 3120772

1F. Ring Gear 9. Input Shaft

1G. Housing 10. First Stage Sun Gear
4. Output Carrier Subassembly 11. Second Stage Sun Gear
5. Retaining Ring 18. O-ring
6. Cover Assembly 19. Flat Head Bolts
6G. Retaining Ring 20. Retaining Ring
Figure 3-3. Main Disassembly Drawing 2
3120772 – JLG Lift – 3-7

Output Carrier Disassembly 3. Using a 1/8" diameter punch, drive the Roll Pin (4G)
out of the Planet Shaft (4E). NOTE: The Roll Pins
1. Using a 1/8" diameter punch, drive the Roll Pin (4G) (4G) should not be reused when reassembling the
unit.
into the Planet Shaft (4E) until it bottoms against the
Carrier (3A). 4. Slide the Planet Gear Sub-assembly (4) out of the
Output Carrier (4A) being careful to not drop the
2. Using a soft face hammer, tap the Planet Shaft (4E) Needle Bearings (4C) in the process.
out of the Carrier (4A).
4A Output Carrier 4E Planet Shaft

4B Thrust Washer 4F Planet Gear
4C Needle Bearing 4G Roll Pin
4D Thrust Spacer 4H Thrust Washer
Figure 3-4. Output Carrier
3-8 – JLG Lift – 3120772

5. Remove 4 Thrust Washers (4B), 28 Needle Rollers 6. Repeat Steps 1 though 5 for the remaining two
(4C) and the Thrust Spacer (4D) from the Second Planet Gears (4F).
Stage Planet Gear (4F).
7. Remove the Thrust Washer (4H) from the counter-
bore in the Output Carrier (4A).
1F Output Carrier
4B Thrust Washer
4C Needle Bearing
4D Thrust Spacer
4F Planet Gear
Figure 3-5. Planet Gear
3120772 – JLG Lift – 3-9

Input Carrier Disassembly (4G) should not be reused when reassembling the
unit.
1. Using a 1/8" diameter punch, drive the Roll Pin (4G)
into the Planet Shaft (3E) until it bottoms against the 4. Slide the Planet Gear (3F) and the two Thrust Wash-
Carrier (3A). ers (3B) out of the Carrier (3A).
2. Using a soft face hammer, tap the Planet Shaft (3E) 5. Remove the 14 needle Bearings (3C) from the bore
out of the Carrier (3A). of the Planet Gear (3F).
3. Using a 1/8" diameter punch, drive the Roll Pin (4G) 6. Repeat steps 1 through 5 for each of the two remain-
out of the Planet Shaft (3E). NOTE: The Roll Pins ing planet gears.
3A Carrier
3B Thrust Washer
3C Needle Bearing
3E Planet Shaft
3F Planet Gear
4G Roll Pin
Figure 3-6. Input Carrier
3-10 – JLG Lift – 3120772

Hub-Spindle Disassembly 6. If necessary, press 9 Studs (1H) out of Hub (1G).

Locate Hub (1G) on Seal (1B) end.
1. Place unit on bench with Spindle (1 A) end down.
7. Remove Seal (1B) from Hub (1G).
2. Remove Retaining Ring (1J) with appropriate tool.
NOTE: The Seal (1B) should NOT be reused when reassem-
3. Remove Spacer (1N). bling the unit.
4. Remove "A" position Bearing Cone (1C) from Bear- 8. Remove "B" position Bearing Cone (1E) from Hub
ing Cup (1D) in Hub (1G). (1G).
5. Lift Hub (1G) off of Spindle (1 A). Remove Boot Seal 9. Using a soft steel rod, knock both Bearing Cups
(1Q) from Hub (1G) if applicable. (1D) out of Hub (1G).
1A Spindle 1H Stud
1D Tapered Bearing Cup 1J Retaining Ring Ext.
1E Tapered Bearing Cone 1N Spacer
1G Hub(Housing) 1Q Seal Boot
Figure 3-7. Hub Spindle
3120772 – JLG Lift – 3-11

Cover Disassembly 4. Pull Disengage Rod (6D) out from Cover (6A).
1. Remove O-Ring (17) from groove in Cover (6A). 5. Use appropriate tool to remove O-ring (6E) from
internal groove in Cover (6A).
2. Remove Thrust Washer (2) from Cover (6A) pockets.
3. Unscrew two Hex Head Bolts (6C) and remove Dis- 6. Remove two O-Ring Pipe Plugs (6F) from Cover
engage Cap (6B) from Cover (6A). (6A).
2 Thrust Spacer
3A Input Carrier
6A Cover
6B Disengage Cap
6C Bolt, Hex
6D Dowel Pin
6E O-ring
6F Pipe Plug
17 O-ring
Figure 3-8. Cover Assembly
3-12 – JLG Lift – 3120772

Input Carrier Assembly Output Planet Gear Assembly

(Refer to Figure 3-6., Input Carrier) (Refer to Figure 3-5., Planet Gear)
1. Apply a liberal coat of grease to the bore of one 1. Apply a liberal coat of grease to the bore of one Out-
Input Planet Gear (3F). put Planet Gear (4F).
2. Line the inside of the Planet Gear (3F) with 14 Nee-
2. Line the inside of the Planet Gear (4F) with 14 Nee-
dle Rollers (3C).
dle Rollers (4C).
NOTE: The last roller installed must be installed end wise.
That is, the end of the last roller must be placed in NOTE: The last roller installed must be installed end wise.
between the ends of the two rollers which form the That is, the end of the last roller must be placed in
space, and then slid, parallel to the other rollers, into between the ends of the two rollers which form the
place. space, and then slid, parallel to the other rollers, into
place.
3. Set Carrier (3A) in an upright position.
3. Place Spacer (4D) into the bore of the Output Planet
4. Insert a Planet Shaft (3E) into the planet shaft hole in (4F).
the end of the Carrier (3A) opposite the splined end.
The end of the planet shaft that does NOT have the 4. Repeat Step 2 to put in second roll of Needle Rollers
roll pin hole should be inserted into the carrier (4C).
FIRST.
5. Apply grease to hold two Thrust Washers (4B)
5. Place one Thrust Washer (3B) onto the end of Planet together and onto Output Planet Gear (4F) counter-
Shaft (3E). Make sure the flat faces towards the bore. Do the same to the other side.
inside of the carrier and make sure the button fits in
the pocket on the inside of the Carrier (3A) towards 6. Repeat Steps 1 -5 to finish the assembly of the two
the OD. remaining Output Planet Gears (4F).
6. Following the thrust washer, place Planet Gear (3F)
with needle rollers, onto Planet Shaft (3E).
7. Following the planet gear, place one more Thrust
Washer (3B) onto Planet Shaft (3E). Align the Thrust
Washer (3B) in the same manner described in Step
5.
8. Now insert Planet Shaft (3E) through the opposite
planet shaft hole on Carrier (3A). Use an alignment
punch or similar tool to align the roll pin holes on
Carrier (3A) and Planet Shaft (3E).
NOTE: Be sure not to hit the Planet Gears (3F) when driving
in the Roll Pins (4G).
9. Drive Roll Pin (4G) down into the aligned roll pin
holes. Pin should be flush with the flat of carrier.
10. Repeat Steps 1-9 for the installation of the two
remaining Planet Gears (3F).
NOTE: Some grease may need to be applied to the Thrust

Washers (3B) to hold them in place while installing
the planet gears.
3120772 – JLG Lift – 3-13

Output Carrier Assembly Hub-Spindle Assembly

(Refer to Figure 3-4., Output Carrier) (Refer to Figure 3-7., Hub Spindle)
1. Place Thrust Washer (4H) into counterbore of Carrier NOTE: Spray a light film of oil on all component parts during
(4A). BE SURE the small diameter side of Washer assembly.
(4H) facing planet gear side. 1. Place Hub (1G) into pressing base. Press nine Studs
(1H) into Hub.
2. Place Planet Gear Sub-assembly (4) into Carrier
(4A). Visually align the planet gear bore with one of NOTE: Use enough pressure to press in studs. Don’t use
the planet shaft holes on the Carrier (4A). excessively high pressure to press in studs or hub
may crack.
3. Insert a Planet Shaft (4E) into the planet shaft hole
described in Step 2 on Carrier (4A). The end of the NOTE: Spray a generous amount of oil on bearings during
planet shaft that does NOT have the roll pin hole installation.
should be inserted into the Carrier (4A) FIRST.
2. Press Bearing Cup (1D), position "A", into Hub (1G)
4. Now insert Planet Shaft (4E) through the first set of using appropriate pressing tool.
Thrust Washers (4B), Planet gear, then the second
3. Turn hub over and press Bearing Cup (1D), position
set of Thrust Washers (4B). Use an alignment punch
"B", into hub using appropriate pressing tool.
or similar tool to align roll pin holes on Carrier (4A)
and Planet Shaft (4E). 4. Place Bearing Cone (1E), into Bearing Cup (1D),
position "B".
NOTE: Be sure not to hit the Planet Gears (4F) when driving
in Roll Pins (4G). 5. Grease Seal (1B) lip and press seal into Hub (1G)
using appropriate tool until seal is flush with end of
5. Drive Roll Pin (4G) down into the aligned roll pin hub.
holes. Pin should be flush with OD of Carrier (4A).
6. Press Seal Boot (1Q) onto Hub (1G) if required. Turn
6. Repeat Steps 1-5 for the installation of the two Hub (1G) over and lower onto Spindle (1A).
remaining Planet Gears (4F).
7. Install Bearing Cone (1C) into Bearing Cup (1D),
position "A".
8. Place Bearing Spacer (1N) on top of Bearing Cone
(1C).
9. Using appropriate tool, install Retaining Ring (1J)
into Spindle (1A) groove. Make sure ring is com-
pletely seated in groove.
NOTE: Extra bearing pre-load caused by using tool in Step

#9 must be removed. This should be done by plac-
ing a tool (NOT THE SAME TOOL USED IN STEP #9)
on the end of the spindle, and then striking the tool
with a piece of barstock. This should be adequate to
remove any additional bearing pre-load.
3-14 – JLG Lift – 3120772

Cover Subassembly Main Assembly

(Refer to Figure 3-8., Cover Assembly) (Refer to Figure 3-2., Main Disassembly Drawing 1 and
Figure 3-3., Main Disassembly Drawing 2)
1. Grease O-Ring (6E) and insert into internal groove in
Cover (6A). NOTE: All components should receive a generous amount
of lubricant oil as they are being assembled.
2. Assemble Disengage Cap (6B) onto Cover (6A)
using two Hex Head Bolts (6C). Torque bolts to 70- 1. Place Hub-Spindle Sub-Assembly on the bench.
80 in-lbs.
2. Grease O-Ring (18) and place it into groove of Hub
3. Insert Disengage Rod (6D) into hole in Cover (6A) (1G).
until it touches the inside of the Disengage Cap (6B).
3. Place Ring Gear (1F) onto Hub (1G). Align the three
NOTE: The Disengage Rod can be inserted either end first. shipping Cap Screw Holes on Hub (1G) and Ring
Gear (1F).
4. Grease Face of Thrust Washer (2) and place in
Cover (6A) making sure that tangs on washer seat 4. Install three shipping Cap Screws (19) into ring gear
into pockets in cover. and hub. Torque them to 15-20 ft-lbs.
5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The 5. Place Output Carrier Sub-Assembly (4) into mesh
plugs should be hand tight according to SAE stan-
with Spindle (1A) splines.
dard.
6. Place External Retaining Ring (5) over 13T spline to
the retaining groove on Input Shaft (9).
NOTE: For ratio 48:1, assemble Output Sun Gear (11) over
Input Shaft (9) first, then install External Retaining
Ring (5).
7. Using appropriate tool to install Retaining Ring (20)

into groove on Output Sun (11)
8. Place Input Shaft (9) spline end into mesh with Inter-
nal Coupling (7) splines.
9. With the modified spline end facing up, place the

Output Sun Gear (11) into mesh with the output
planet gears.
10. Place Input Carrier Sub-Assembly (3) onto Output

Sun Gear (11) splines. Drop Input Sun (10) into
mesh with planet gears for specific ratios, if
required. (No timing required)
11. Grease O-Ring (17) and insert into groove in Cover

Sub-Assembly (6).
12. Install Cover Sub-Assembly (6) into Ring Gear (1F)

counterbore and install Retaining Ring (6G) into
groove in Ring Gear (1F).
13. Attach ID Tag (15) onto unit using Drive Screws (16).
14. Check disconnect, roll and air check unit, leak check
brake, and record release pressure. 14. Insert Plas-
tic Plug (12) into place if applicable.
3120772 – JLG Lift – 3-15

Figure 3-9. Hub Assembly - Sheet 1 of 2
3-16 – JLG Lift – 3120772

1A Spindle 3B Thrust Washer 6C Bolt, Hex (.250-20 Unc, .500 Gr5)

1B Lip Seal 3C Needle Bearing 6D Dowel Pin
1C Tapered Bearing Cone 3E Planet Shaft 6E O-ring
1D Tapered Bearing Cup 3F Planet Gear 6F Pipe Plug
1E Tapered Bearing Cone 4A Output Carrier 6G Retaining Ring - Int 7.086
1F Ring Gear 4B Thrust Washer 7 Coupling
1G Hub(Housing) 4C Needle Bearing 9 Input Shaft
1H Stud 4D Thrust Spacer 10 Input Sun Gear
1J Retaining Ring Ext. 4E Planet Shaft 11 Output Sun Gear
1K Retaining Ring Int. 4F Planet Gear 15 ID Plate
1L Spring (1.460,1.500) 4G Roll Pin 16 Drive Screw
1M Thrust Washer 4H Thrust Washer 17 O-ring
1Q Seal Boot 5 Retaining Ring - Ext 18 O-ring
2 Thrust Spacer 6A Cover 19 Bolt, Flat Head - Hex Skt (.375-16)
3A Input Carrier 6B Disengage Cap 20 Retaining Ring - Ext.
Figure 3-10. Hub Assembly - Sheet 1 of 2
3120772 – JLG Lift – 3-17

Figure 3-11. Cup Pressing Tool
Figure 3-12. Cup Pressing Tool
3-18 – JLG Lift – 3120772

3.4 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in
cover (21).
Disassembly NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly.
1. Remove pressure plate (3) from cover (21) by
removing the capscrews (1) and washers (2).
5. Install dowel pins (20), spring retainer (16) and
springs (5) in cover plate (21).
PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXI- 6. Position plate (14) on springs (15). NOTE: Disc (13
MATELY 1500 LBS (680 KGF). THE FOUR CAP SCREWS SHOULD &11) and plate (14) must remain dry during
BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAU- installation. No oil residue must be allowed to
LIC PRESS IS AVAILABLE, 3000 LBS (1361 KGF) MINIMUM, THE contaminate disc surfaces.
PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING
THE CAP SCREWS AND WASHERS 7. Press the speed sensor ring (12) onto the rotor disc
(13).
2. Remove case seal (4) from cover (21).
8. Place a new rotor disc (13) on the shaft (10) until it
3. Remove piston (7) from pressure plate (3). contacts the plate (14). Install stator disc (11).
4. Remove o-ring (5), back-up ring (6), o-ring (8) and 9. Install new o-ring (5), new back-up ring (6), new o-
back-up ring (9) from piston (7). ring (8) and new back-up ring (9) on piston (7). Note
order of o-rings and backup rings. Insert piston (7)
into pressure plate (3). Be careful not to shear o-
IF THE SENSOR RING (12) IS DAMAGED OR NEEDS REPLACED, rings or back-up rings.
THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT. THE SEN-
SOR RING IS NOT AVAILABLE AS A SERVICE PART. 10. Install new case seal (4) in cover (21).
5. Remove stack assembly, consisting of stator disc 11. Position pressure plate (3) on cover (21) aligning
(11), sensor ring (12), rotor disc (13), and plate (14) dowel pins (20) with holes in pressure plate.
from cover (21).
NOTE: A hydraulic press will simplify installation of pressure
6. Remove dowel pins (20), springs (15) and spring plate on cover. Clamp pressure plate in position
retainer (16) from cover (21). while tightening the cap screws.
NOTE: Note number and pattern of springs for reassembly

purposes. 12. Install capscrews (1) and washers (2) and tighten
evenly to draw pressure plate (3) to cover (21).
7. Remove retaining ring (17) from cover (21). Torque capscrews to 55 ft.lbs. (74.6 Nm).
8. Remove shaft (10) by pressing or using a soft mallet

on male end of the shaft.
IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
9. Remove retaining ring (19) and bearing (18) from BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED
shaft (10). 2000 PSI (137.9 BAR) UNLESS TWO ADDITIONAL BOLTS ARE
10. Press rotary oil seal (20) from cover (18). USED FOR SUPPLEMENTAL CLAMPING.
Assembly Bleeding
I
NOTE: Lubricate all rubber components from the repair kit

1. Install brake in system and connect pressure lines.
with clean type fluid used in the system.
2. Bleed pressure release section of brake by pressur-
1. Clean all parts thoroughly before assembly. izing side inlet port and allowing air to escape from
2. Press new rotary seal (22) into cover (21). Note top port. Pressure should not exceed 100 psi (6.9
direction of seal bar) during bleeding.
3. Install new bearing (18) and retaining ring (19) on 3. Apply sufficient pressure to release brake and check
shaft (10). for proper operation in system.
3120772 – JLG Lift – 3-19

23
22 NOTE: The speed sensor port in the cover (21)
19 should be 180° from the brake release
port in the pressure plate (3).
21
18
17
16
20
15
14
13
12
11
10
9
8
7
6
5
4
2
1
23
1. Capscrew 7. Piston 13. Rotor Disc 19. Retaining Ring

2. Washer 8. O-ring 14. Plate 20. Dowel Pin
3. Pressure Plate 9. Backup Ring 15. Spring 21. Cover
4. Case Seal 10. Shaft 16. Spring Retainer 22. Rotary Oil Seal
5. O-ring 11. Stator Disc 17. Retaining Ring 23. Gasket
6. Backup Ring 12. Sensor Ring 18. Bearing
Figure 3-13. Drive Brake
3-20 – JLG Lift – 3120772

Table 3-2. Drive Brake Diagnosis
Corrective
Problem Cause Explanation
Action
Brake slips Excessive pressure In hydraulic If there is back pressure in the actuation line of the Check filters. hose size, restrictions
system brake, holding torque will be reduced. in other hydraulic components.
Oil In brake if designed for dry Wet linings generate 67% of the dry torque rating. If Replace oil seal in brake. Check
use the brake has oil In it, check the type of oil hydraulic motor seal. Check piston seals.
or gearbox. Note: Internal components will
1. Gearbox oil need to be inspected, cleaned, and
2. Hydraulic oil replaced as required.
Disc plates worn The thickness of the disc stack sets the torque level. Check disc thickness.
A thin stack reduces torque.
Springs broken or have taken a Broken or set springs can cause reduced torque - Check release pressure.
permanent set rare occurrence. (See spring replacement)
Brake drags or runs Low actuation pressure The brake should be pressurized to minimum of Place pressure gauge in bleed port
hot 1.38 bar (20 psi) over the full release pressure under & check pressure with system on.
normal operating conditions. Lower pressures will
cause the brake to drag thus generating heat.
Bearing failure If the bearing should fall. a large amount of drag can Replace bearing.
be generated.
Brake will not release Stuck or clogged valve Brakes are designed to come on when system pres- Place pressure gauge in bleed port
sure drops below stated release pressure. If pres- - check for adequate pressure.
sure cannot get to brake, the brake will not release. Replace defective line or compo-
nent.
Bad O-rings f release piston will not hold pressure, brake will not Replace o-rings.
release.
Discs frozen These brakes are designed for only limited dynamic Replace disc stack.
braking. A severe emergency stop or prolonged
reduced release pressure operation may result in
this type of damage.
3120772 – JLG Lift – 3-21

3.5 SPEED SENSOR ADJUSTMENT 3.6 POSITRAC/TILT MODULE

When installing a new positrac/tilt module, Refer to
JLG Control System Analyzer Kit instructions. Use a
standard bubble level in two different directions to
ensure that the machine’s frame is level prior to install-
ing the new positrac/tilt module.
1. Place the machine on a flat, level surface. Check for
level by placing a bubble level on the frame in both
directions.
2. Plug in the analyzer (Analyzer - p/n 1600244, Cable -
p/n 1600633) into port J9 on the power module or
port J1 on the platform module.
3. Use the right arrow key to curse over to “ACCESS
FOR PROPER DRIVE OPERATION, THE SPEED SENSORS (2) LEVEL 2". Depress Enter.
MUST BE PROPERLY INSTALLED AND ADJUSTED. THE SENSOR
OPERATES ON A LEADING PULSE TO SHOW DIRECTION. IF 4. Use Up/Down arrow keys to enter the following
INSTALLED INCORRECTLY, THE SENSOR WILL NOT BE ABLE TO password “33271”. Depress Enter.
SENSE THE PROPER DIRECTION. IF BOTH SENSORS ARE 5. Use the right arrow key to curse over to “LEVEL
INSTALLED INCORRECTLY, THE JLG CONTROL SYSTEM WILL VEHICLE”. Hit Enter. Depress Enter again.
THINK THE MACHINE IS ON A HILL AND THE MACHINE WILL GO
INTO FULL SPEED MODE IMMEDIATELY. IF ONLY ONE SENSOR IS 6. Verify that the tilt reading is now “0.0; 0.0".
INSTALLED WRONG, THE CONTROLLER SENSES A PROBLEM
AND THE MACHINE WILL ONLY DRIVE AT CREEP SPEED. IF BOTH
SENSORS ARE ADJUSTED TOO FAR OUT, THE CONTROL SYSTEM
TO ASSURE PROPER OPERATION, THE MACHINE MUST BE LEVEL
WILL NOT DRIVE THE MACHINE.
WHEN ADJUSTING OR INSTALLING AND CALIBRATING A NEW
POSITRAC/TILT MODULE
Adjustment Procedure
1. Back off the locking nut and o-ring.
2. Thread the sensor in to bottom. (do not force).
3. Back-off 1-2 turns and align the notch with the axis
of the brake
4. Use a 1/2” wrench to hold the sensor and a 3/4”

wrench to snug the lock nut to the brake.
3-22 – JLG Lift – 3120772

Figure 3-14. Speed Sensor Orientation. (E300)
3120772 – JLG Lift – 3-23

Fuse Box
U/L Machines Only
JLG P/N
1600292
MOTOR A MOTOR B
1704246-D
Figure 3-15. Frame Mounted Electrical Components
3-24 – JLG Lift – 3120772

6
1
2 7
3
5 12
4
11 13
14
19 18
21
9
20
24
22
26 23 14
15
25 11 8
27 10
16
30 17
29
28
1. Bolt 7. Hub/Spindle Assembly 13. Thrust Bearing 19. Seal 25. Tanged Washer
2. Keeper 8. Tie Rod 14. Bushing 20. Bearing Cone 26. Castle Nut
3. Pin 9. Shoulder Bolt 15. Castle Nut 21. Bearing Cup 27. Dust Cap
4. Flatwasher 10. Locknut 16. Flatwasher 22. Hub 28. Cotter Pin
5. Steer Cylinder 11. Bearing 17. Cotter Pin 23. Bearing Cup 29. Lug Nut
6. Shoulder Bolt 12. King Pin 18. Spindle 24. Bearing Cone 30. Stud
Figure 3-16. Steering Components and Spindle
3120772 – JLG Lift – 3-25

Figure 3-17. Drive Components
3-26 – JLG Lift – 3120772

3.7 SWING BEARING 2. Check the turntable to bearing. Attach bolts as fol-
lows:
Turntable Bearing Mounting Bolt Condition a. On a firm level surface, elevate the fully retracted
Check boom to 70 degrees (full elevation).
b. At the positions indicated on Figure 2-19. try and

NOTE: This check is designed to replace the existing bear-
insert the.0015” feeler gauge between the bolt
ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of head and hardened washer at the arrow indi-
machine operation and every 600 hours of machine cated position.
operation thereafter. If during this check any bolts c. Lower the boom to horizontal and fully extend
are found to be missing or loose, replace missing or the boom.
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt d. At the position indicated on Figure 2-17 try and
threads with loctite #271. After replacing and insert the.0015” feeler gauge between the bolt
retorquing bolt or bolts recheck all existing bolts for head and hardened washer at the arrow indi-
looseness. cated position.
1. Check the frame to bearing. Attach bolts as follows:
a. On a firm level surface, elevate the fully retracted

boom to 70 degrees (full elevation).
b. At the position indicated on Figure 2-20. try and
insert the.0015” feeler gauge between the bolt
head and hardened washer at the arrow indi-
cated position.
c. Assure that the.0015” feeler gauge will not pene-
trate under the bolt head to the bolt shank.
d. Swing the turntable 90 degrees, and check
some selected bolts at the new position.
Figure 3-18. Swing Bearing Feeler Gauge Check
e. Continue rotating the turntable at 90 degrees
intervals until a sampling of bolts have been
checked in all quadrants.
3120772 – JLG Lift – 3-27

Wear Tolerance Replacement of Swing Bearing

1. Removal.
1. With the boom positioned over the side of the
machine, the Upper Boom horizontal with telescope a. Attach an adequate support sling to the boom
fully extended and Tower Boom raised half way and draw all slack from sling. Prop or block the
(approx 37°)See Figure 2-22, using a magnetic base boom if feasible.
dial indicator, measure and record the distance b. Tag and disconnect hydraulic lines running
between the swing bearing and turntable. (See Fig- through center of turntable and frame. Use a
ure 2-20) suitable container to retain any residual hydrau-
lic fluid. Cap lines and ports.
2. At the same point, with the boom positioned over
the side of the machine, the Upper Boom fully c. Attach suitable overhead lifting equipment to the
retracted, the platform rotated max. to the side, and base of turntable weldment.
the Tower Boom fully elevated, (See Figure 2-21) d. Use a suitable tool to scribe a line on the inner
using a magnetic base dial indicator, measure and race of the swing bearing and on the underside
record the distance between the swing bearing and of the turntable. This will aid in aligning the bear-
turntable (See Figure 2-20). ing upon installation. Remove bolts, nuts and
washers which attach the turntable to the bear-
ing inner race. Discard nuts and bolts.
e. Use the lifting equipment to carefully lift the com-
plete turntable assembly from the bearing.
Ensure that no damage occurs to the turntable,
bearing or frame mounted components.
f. Carefully place the turntable on a suitably sup-
ported trestle.
g. Use a suitable tool to scribe a line on the outer
race of the swing bearing and the frame. This
line will aid in aligning the bearing upon installa-
tion. Remove the bolts and washers which
attach the outer race of the bearing to the frame.
Discard the bolts. Use suitable lifting equipment
to remove the bearing and rotation box assem-
Figure 3-19. Swing Bearing Tolerance Measuring Point bly from the frame; move to a clean, suitably
supported work area.
h. Remove the two cap screws securing the bear-
3. If a difference greater than 0.057 in. (1.40 mm) is
ing to the rotation box to separate the two for
determined, the swing bearing should be replaced.
inspection.
4. If a difference less than 0.057 in. (1.40 mm) is deter-
mined, and any of the following conditions exist, the
bearing should be removed.
a. Metal particles in the grease.

b. Increased drive power.
c. Noise.
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble

bearing and return to service.
3-28 – JLG Lift – 3120772

Figure 3-20. Swing Bearing Tolerance Boom Placement.
3120772 – JLG Lift – 3-29

Figure 3-21. Swing Bearing Tolerance Boom Placement
3-30 – JLG Lift – 3120772

j. Use suitable lifting equipment to carefully posi-

2. Installation. tion the turntable assembly above the machine
a. Install bearing to rotation box with two cap frame.
screws, so that fill plug of bearing is as close to k. Carefully lower the turntable onto the swing
gear as bolt pattern will allow. Do not tighten cap bearing. Ensure that the scribed line of the inner
screws. race of the bearing aligns with the scribed mark
on the turntable. If a new swing bearing is used,
b. Line up high spot (blue) of bearing with center
ensure that the filler plug fitting is at 90 degrees
tooth of worm gear. Set backlash to 0.008 -
from the fore and aft centerline of the turntable.
0.010 inch (0.20 - 0.25 mm). Tighten cap screws
as shown in Figure 2-24. l. Apply a light coating of Loctite 271 to the new
bearing bolts and install through the turntable
c. Spray Mobiltac 375NC open gear spray onto
and inner race of bearing.
gear teeth.
m. Following the torque sequence shown in Figure
d. Apply Tribol Molub-Alloy 936 Open Gear Com-
2-24, tighten the bolts to an initial torque of 175
pound to bearing.
ft. lbs. (237 Nm). Then following the same
e. Grease bearing with Mobilith SHC Bearing sequence, tighten the bolts to 240 ft. lbs (326
Grease. Grease fitting is on inside wall of inner Nm).
race of bearing.
n. Remove the lifting equipment.
NOTE: If Tribol Molub-Alloy 936 Open Gear Compound or o. Route hydraulic lines through center of turntable
Mobilith SHC Bearing Grease are not available, and frame and connect as tagged prior to
Multi-Purpose Grease (MPG) can be substituted, removal.
however the service interval will be shorter.
p. Using all applicable safety precautions, activate
f. Using suitable lifting equipment, install bearing/ the hydraulic system and functionally check
rotation box assembly to frame with soft spot swing system for proper and safe operation.
(red) 90 degree relative to load axis. If reusing
old bearing, ensure that scribed line of outer
race of the bearing aligns with the scribed mark
on the frame.
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8

BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED
WITH NEW NUTS AND BOLTS. SINCE THE SWING BEARING IS
THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURN-
TABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT HARD-
WARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG
HARDWARE IS HIGHLY RECOMMENDED.
g. Apply a light coating of Loctite 271 to the new

bearing bolts and loosely install the bolts and
washers through the frame and outer race of
bearing.
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT

WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT
BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD
BE CHECKED PRIOR TO USE.
h. Following the torque sequence diagram shown

in Figure 2-24, tighten the bolts to an initial
torque of 175 ft. lbs. (237 Nm). Then following
the same sequence, tighten to a final torque of
240 ft. lbs. (326 Nm).
i. Remove lifting equipment from bearing.
3120772 – JLG Lift – 3-31

Figure 3-22. Swing Bearing Torquing Sequence

Swing Bearing Torque Value
Install bolts with Loctite - 240 ft. lbs. (326 Nm).
3-32 – JLG Lift – 3120772

Checking Worm Gear End Play

.
JLG Industries requires that a annual inspection be per- Fig 2 Adjusting End Play.
formed on the worm gear end play.
1. Using a dial indicator, measure end play of worm
gear, by applying side to side movement by hand to
platform.
2. If tolerance exceeds.010”, reduce end play to less
than.005”. Refer to Adjusting End Play.
SHIMS
END PLATE
3.8 SWING MOTOR

Removal
Allowable Tolerance
(.001 to .005) 1. Remove the two bolts securing the motor to the
swing drive.
Adjusting End Play 2. Gain access to the hydraulic lines and tag and dis-
connect the lines running to the motor. Cap or plug
1. Remove end plate. all openings.
2. Measure and record total thickness of existing shim
pack.
Disassembly
3. Determine thickness of shim pack required to NOTE: Before disassembling the motor, it is highly recom-
obtain.001” -.005” end play. mended that paint or a marker be used to make a V
shaped set of lines from the end cover to the hous-
4. Adjust shim pack thickness as required to obtain
ing to aid in proper assembly. It is also important that
proper end play. Reduce end play by removing
the steps involving timing be followed carefully to
thicker shims and replacing with thinner shims,
insure proper motor operation.
included in kit.
5. Replace end plate and torque bolts to 90 ft. lbs. (122 1. Remove all shaft related components from the shaft
Nm). (i.e. keys, wire rings, nuts). To aid in assembly of the
motor, make a V shaped set of lines from the end
6. Recheck end play. cover to the housing using either paint or a marker.
2. With the shaft facing down, secure the motor in a

vise by clamping onto the housing.
3. Loosen and remove the bolts holding the motor

assembly together.
4. Remove the end cover.
5. Remove the body seal and discard the seal.
6. Remove the rotor assembly and wear plate. Remove

the body seals from the rotor and housing and dis-
card the seals.
7. Remove the drive link pin and drive link from the
motor and lay aside.
3120772 – JLG Lift – 3-33

8. Gently tap the shaft upward through the housing 3. Install the shaft seal down onto the shaft making
and remove through the rear of the housing. Turn sure the lip on the seal faces down. Refer to Figure
the shaft over and remove the cooling plug. 3-23., Seal Orientation.
9. Remove the housing from the vise and turn over. Pry METAL TEFLON
the dust seal from the housing. BACKUP SEAL BACKUP
DUST SEAL SHIM CARRIER SEAL
10. Push the seal carrier, thrust washer, and thrust bear-
ing down and remove from the rear of the housing.
NOTE: When removing the seal carrier, thrust washer, and

thrust bearing take care not to scratch or nick the
housing bore.
11. If a new seal carrier and thrust washer are included

in the repair kit, the old items may be discarded. If
not, carefully pry the shaft seal, teflon backup seal,
and metal backup shim from the seal from the seal
carrier and discard the metal backup shim, backup
seal, and shaft seal. Lay the seal carrier aside. SPLIT WIRE HIGH METAL SHAFT
12. Remove the wire ring, metal backup shim, and high RING PRESSURE BACKUP SEAL
pressure seal from the inner bore groove of the SEAL SHIM
housing with a small screwdriver and discard them. Figure 3-23. Seal Orientation
13. All parts should be cleaned in an oil based solvent
and dried using compressed air. All new seals 4. Install the teflon backup seal onto the shaft with the
should be lightly coated in clean oil prior to installa- flat side up and the seal lip facing the shaft seal.
tion.
5. Place the metal backup shim onto the shaft and
against the teflon backup seal.
Assembly
6. Place the seal carrier onto the shaft (large end
down) and carefully press the seal carrier down onto
the seal assembly using an arbor press and sleeve
FOR PROPER OPERATION, THE MOTOR DEPENDS ON THE COR-
to compress the seals into the carrier.
RECT ORIENTATION OF PARTS AS WELL AS THE CORRECT
INTERNAL TIMING. 7. Install the high pressure seal into the groove in the
housing.
1. Place the shaft on a clean flat surface with the output
8. Install the metal backup shim against the high pres-
end facing up.
sure seal in the groove in the housing bore by
2. Place the thrust bearing, then thrust washer, on the squeezing the shim between the thumb and forefin-
shaft. ger to bow shim (bow in the shim should be in the
shape of a hill and not a valley for easier installation).
9. While maintaining the bow in the shim, start the shim
into the groove and use a small screwdriver to push
the shim into the groove. Install the wire ring into the
groove making sure the ends are butted.
Shaft Timing Procedure
FOR PROPER OPERATION, THE MOTOR DEPENDS ON THE COR-

RECT ORIENTATION OF PARTS AS WELL AS THE CORRECT
INTERNAL TIMING.
1. Turn shaft over so the output end of the shaft faces

down.
2. Install the cooling plug into the shaft making sure
the large OD end of the cooling plug faces up.
3-34 – JLG Lift – 3120772

3. Lower the drive link into the shaft making sure that 11. Lower the rotor onto the drive link making sure the
the timing mark end of the drive link faces up and timing mark on the drive link is aligned with a peak
the timing mark on the end of the drive link is on the rotor as shown in Figure 3-25., Timing Mark.
aligned with one of the through holes in the shaft.
4. When the splines contact each other, slowly rotate TIMING MARK PEAK ON ROTOR
the drive link counterclockwise until the drive link
splines engage with those on the shaft.
5. Turn the housing over so the pilot of the housing
faces down and secure the housing in a vise.
6. Without disturbing the seal carrier assembly or drive
link, carefully lower the shaft assembly into the
housing.
7. To seat the seal carrier against the wire ring, gently
tap the drive link down until the end of the shaft is
nearly flush with the rear surface of the housing.
8. Place a body seal in the groove in the rear surface of
the housing.
9. Using alignment marks as a guide, place the wear Figure 3-25. Timing Mark
plate on the housing making sure the notch in the
wear plate is aligned with the port side of the hous-
12. Once splines are engaged, rotate rotor so the notch
ing as shown in Figure 3-24., Notch Alignment.
on the rotor is aligned with the notch on the wear
NOTCH IN ROTOR plate and the ports on the housing. Refer to Figure
3-24., Notch Alignment.
NOTCH IN STATOR
13. Insert the drive link pin into the end of the drive link
making sure the concave end faces up.
HOUSING
PORTS 14. Place the remaining body seal in the groove in the
end cover.
15. Using alignment marks as a guide, place the end

cover onto the motor making sure the end of the
drive link pin is in the hole in the center of the end
cover.
16. Insert the four bolts and torque to an initial value of

10 ft.lbs. (13.5 Nm). Using a criss-cross pattern,
Figure 3-24. Notch Alignment apply a final torque of 50 ft.lbs. (68 Nm).
10. Place a body seal in the grove in the face of the 17. Remove the motor from the vise and place on a
rotor. clean work surface with the shaft facing up. Making
sure the lip seal faces up, place the dust seal over
the shaft. Using a seal and hammer, carefully drive
the dust seal into place.
Installation
1. Connect the two hydraulic lines to the motor as
tagged during Removal.
2. Position the motor on the swing drive and secure in

place with the retaining bolts. Apply Loctite to the
bolts and torque to 120 ft.lbs. (163 Nm).
3120772 – JLG Lift – 3-35

1. Dust Seal 6. Shaft Seal 11. Ball 16. Drive Link Pin
2. Retainer Ring 7. Thrust Washer 12. Cooling Plug 17. Bolt
3. Backup Shim 8. Thrust Bearing 13. Housing 18. Shaft
4. Housing Seal 9. Wear Plate 14. Drive Link 19. Key
5. Body Seal 10. End Cover 15. Rotor Set
Figure 3-26. Swing Motor
3-36 – JLG Lift – 3120772

11
7
201
103
104
102
SWING ROTATION BOX SWING3 MOTOR
105 4
1
101
SWING BEARING
Figure 3-27. Swing Components
3120772 – JLG Lift – 3-37

3.9 HELAC ROTARY ACTUATOR

Theory Of Operation
The rotary actuator is a simple mechanism that uses
the sliding spline operating concept to convert linear
piston motion into powerful shaft rotation. Each actua-
tor is composed of a housing with integrated gear
teeth (01) and only two moving parts: the central shaft
with integrated bearing tube and mounting flange (02),
and the annular piston sleeve (03). Helical spline teeth
machined on the shaft engage matching splines on the
in-side diameter of the piston. The outside diameter of
the piston carries a second set of splines, of opposite
hand, which engage with matching splines in the hous-
ing. As hydraulic pressure is applied, the piston is dis-
placed axially within the housing -similar to the
operation of a hydraulic cylinder while the splines
cause the shaft to rotate. When the con-trol valve is
closed, oil is trapped inside the actuator, preventing
piston movement and locking the shaft in position.
The shaft is supported radially by the large upper radial
bearing and the lower radial bearing. Axially, the shaft NOTE: Bars indicate starting positions of piston and shaft.
is separated from the housing by the upper and lower Arrows indicate direction they will rotate. The hous-
thrust washers. The end cap is adjusted for axial clear- ing with integral ring gear remains stationary.
ance and locked in position by set screws or pins. As fluid pressure is applied, the piston is displaced
axially while the helical gearing causes the piston
and shaft to rotate simultaneously. The double helix
design compounds rotation: shaft rotation is about
twice that of the piston.
3-38 – JLG Lift – 3120772

1. Housing 200. T-Seal 304. Thrust Washer

2. Shaft 202. T-Seal 304.1. Wiper Seal
3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional)
4. End Cap 205. Cup Seal 401. Counterbalance Valve
109. Lock Pin 207. Back-Up
113. Cap Screw 302. Wear Guide
Figure 3-28. Rotary Actuator (Exploded View)
3120772 – JLG Lift – 3-39

1. Housing 200. T-Seal 304. Thrust Washer

2. Shaft 202. T-Seal 304.1. Wiper Seal
3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional)
4. End Cap 205. Cup Seal 401. Counterbalance Valve
109. Lock Pin 207. Back-Up
113. Cap Screw 302. Wear Guide
Figure 3-29. Rotary Actuator (Cutaway View)
3-40 – JLG Lift – 3120772

Tools Required for Assembly/Disassembly Disassembly

Upon assembly and disassembly of the actuator there
are basic tools required. The tools and their intended
functions are as follows:
1. Flashlight- helps examine timing marks, component

failure and overall condition.
2. Felt Marker- match mark the timing marks and out-

line troubled areas.
3. Allen wrench- removal of port plugs and setscrews.
4. Box knife- removal of seals.
5. Seal tool- assembly and disassembly of seals and

wear guides.
1. Remove the cap screws (113) over end cap lock
6. Pry bar- removal of end cap and manual rotation of
pins (109).
shaft.
7. Rubber mallet- removal and installation of shaft and

piston sleeve assembly.
8. Nylon drift- installation of piston sleeve.
9. End cap dowel pins- removal and installation of end

cap (sold with Helac seal kit).
2. Using a 1/8” (3.18mm) drill bit, drill a hole in the cen-

ter of each lock pin to a depth of approximately 3/
16” (4.76mm).
The seal tool is merely a customized standard flat head 3. Remove the lock pins using an “Easy Out” (a size
screwdriver. To make this tool you will need to heat the #2 is shown). If the pin will not come out with the
flat end with a torch. Secure the heated end of the “Easy Out”, use 5/16” drill bit to a depth of 1/2”
screwdriver in a vice and physically bend the heated (12.7mm)todrill out the entire pin.
end to a slight radius. Once the radius is achieved
round off all sharp edges of the heated end by using a
grinder. There may be some slight modifications for
your own personal preference.
3120772 – JLG Lift – 3-41

4. Install the end cap (4) removal tools provided with 7. Remove the stop tube if included. The stop tube is
the Helac seal kit. an available option to limit the rotation of the actua-
tor.
5. Using a metal bar, or something similar, un-screw

the end cap (4) by turning it counter clock-wise.
8. Every actuator has timing marks for proper engage-

ment.
6. Remove the end cap (4) and set aside for later
inspection.
3-42 – JLG Lift – 3120772

9. Prior to removing the shaft, (2), use a felt marker to 12. To remove the piston (3) use a rubber mallet and a
clearly indicate the timing marks between shaft and plastic mandrel so the piston is no damaged.
piston. This will greatly simplify timing during assem-
bly.
13. At the point when the piston gear teeth come out of
engagement with the housing gear teeth, mark the
10. Remove the shaft (2). It may be necessary to strike piston and housing with a marker as shown.
the threaded end of the shaft with a rubber mallet.
14. Remove the o-ring (204) and backup ring (207) from
11. Before removing the piston (3), mark the housing (1) end cap (4) and set aside for inspection.
ring gear in relation to the piston O.D. gear. There
should now be timing marks on the housing (1) ring
gear, the piston (3) and the shaft (2).
3120772 – JLG Lift – 3-43

15. Remove the wear guides (302) from the end cap (4) 18. Remove the wiper seal (304.1) from its groove in the
and shaft (2).
end cap (4) and shaft (2).
16. To remove the main pressure seals (205), it is easi-

est to cut them using a sharp razor blade being 19. Remove the piston O.D. seal (202).
careful not to damage the seal groove.
17. Remove the thrust washers (304), from the end cap 20. Remove the piston I.D. seal (200). You may now pro-
(4) and shaft (2). ceed to the inspection process.
3-44 – JLG Lift – 3120772

Inspection Assembly
1. Gather all the components and tools into one loca-

1. Clean all parts in a solvent tank and dry with com-
tion prior to re-assembly. Use the cut away drawing
pressed air prior to inspecting. Carefully inspect all
to reference the seal orientations.
critical areas for any surface finish abnormalities:
Seal grooves, bearing grooves, thrust surfaces, rod
surface, housing bore and gear teeth.
2. Install the thrust washer (304) onto shaft (2) and end
cap (4).
2. Inspect the thrust washers (304) for rough or worn

edges and surfaces. Measure it’s thickness to make
sure it is within specifications (Not less than 0.092”
or 2.34 mm).
3. Install the wiper seal (304.1/green O-ring) into it’s

groove on the shaft (2) and end cap (4) around the
outside edge of the thrust washer (304).
3. Inspect the wear guide condition and measure thick-

ness (not less than 0.123” or 3.12 mm).
3120772 – JLG Lift – 3-45

4. Using a seal tool install the main pressure seal (205) 7. Beginning with the inner seal (200) insert one end of
onto shaft (2) and end cap (4). Use the seal tool in a
b/u ring in the lower groove and feed the rest in
circular motion.
using a circular motion. Make sure the wedged ends
overlap correctly. Repeat this step for the outer seal
(202).
5. Install the wear guide (302) on the end cap (4) and
shaft (2).
8. Insert the piston (3) into the housing (1) as shown,

until the outer piston seal (202) is touching inside
the housing bore.
6. Install the inner T-seal (200) into the piston (3) using
a circular motion. Install the outer T-seal (202) by
stretching it around the groove in a circular motion.
Each T-seal has 2 back-up rings (see drawing for ori-
entation).
9. Looking from the angle shown, rotate the piston (3)
until the marks you put on the piston and the hous-
ing (1) during disassembly line up as shown. Using
a rubber mallet, tap the piston into the housing up to
the point where the gear teeth meet.
3-46 – JLG Lift – 3120772

10. Looking from the opposite end of the housing (1) 13. Install 2 bolts in the threaded holes in the flange.
Using a bar, rotate the shaft in a clockwise direction
you can see if your timing marks are lining up. When
until the wear guides are seated inside the housing
they do, tap the piston (3) in until the gear teeth
bore.
mesh together. Tap the piston into the housing the
rest of the way until it bottoms out.
14. Install the stop tube onto the shaft end. Stop tube is
an available option to limit the rotation of an actua-
11. Install the shaft (2) into the piston (3). Be careful not tor.
to damage the seals. Do not engage the piston gear
teeth yet.
15. Coat the threads on the end of the shaft with anti-
seize grease to prevent galling.
12. Looking from the view shown, use the existing tim-
ing marks to line up the gear teeth on the shaft (2)
with the gear teeth on the inside of the piston (3).
Now tap the flange end of the shaft with a rubber
mallet until the gear teeth engage.
3120772 – JLG Lift – 3-47

16. Install the O-ring (204) and back-up ring (207) into 19. Place the lock pins (109) provided in the Helac seal
the inner seal groove on the end cap (4).
kit in the holes with the dimple side up. Then, using
a punch, tap the lock pins to the bottom of the hole.
17. Thread the end cap (4) onto the shaft (2) end. Make
sure the wear guide stays in place on the end cap as
it is threaded into the housing (1). 20. Insert the set screws (113) over the lock pins.
Tighten them to 25 in. lbs. (2.825 Nm).
18. Tighten the end cap (4). In most cases the original
holes for the lock pins will line up.
3-48 – JLG Lift – 3120772

3.10 BATTERY MAINTENANCE AND Charging Sequence of Remote LED Card

CHARGING 1. Plug in charger.
2. All three LED’s (light emitting diode) flash three
Battery Maintenance, Quarterly times.
1. Open battery compartment cover to allow access to 3. In sequence.
battery terminals and vent caps.
a. Green LED flashes once.
b. Yellow LED flashes once.
WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELEC- c. Red LED flashes once.
TROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS 4. All Three LED flash three times.
ELECTROLYTE COVERS THE PLATES.
5. Yellow LED comes on indicates charger is charging.
NOTE: When adding distilled water to batteries, non-metallic 6. Yellow LED will stay on until fully charged and green
containers and/or funnels must be used. LED will illuminate.
To avoid electrolyte overflow, add distilled water to 7. If Red LED remains on, this indicates a fault.
batteries after charging.
When adding water to the battery, fill only to level

indicated or 1.5 cm (3/8”) above separators.
2. Remove all vent caps and inspect electrolyte level of

each cell. Electrolyte level should be to the ring
approximately one inch from top of battery. Fill bat-
teries with distilled water only. Replace and secure
all vent caps.
3. Remove battery cables from each battery post one

at a time, negative first. Clean cables with acid neu-
tralizing solution (e.g. baking soda and water or
ammonia) and wire brush. Replace cables and/or
cable clamp bolts as required.
4. Clean battery post with wire brush then reconnect

cable to post. Coat non-contact surfaces with min-
eral grease or petroleum jelly.
Figure 3-30. Remote LED Card
5. When all cables and terminal posts have been
cleaned, ensure all cables are properly positioned
and do not get pinched. Close battery compartment
cover.
6. Start hydraulic system and ensure that it functions

properly.
3120772 – JLG Lift – 3-49

10
5 13
7
11
11
2 10
15* 11
11
2 11
11
11
2
11
6
7
12 9
8
14
NOTE: Apply Item #10 to contacts of Anderson connectors only.
NOTE: Apply Item #11 to Battery Terminal connections only.
* Torque to 70 ft.lbs. (95 Nm)
1. Battery 5. Hold Down 9. Shim 13. Battery Box

2. Cable 6. Insulation Grommet 10. Dielectric Grease 14. Battery Box Liner
3. Cover 7. Loctite #242 11. Battery Terminal Grease 15. Shoulder Screw
4. Cover 8. Wear Pad 12. Battery Box
Figure 3-31. Battery Installation
3-50 – JLG Lift – 3120772

Figure 3-32. Battery Cable Connections
3120772 – JLG Lift – 3-51

NOTES:
3-52 – JLG Lift – 3120772

SECTION 4. BOOM & PLATFORM
4.1 BOOM MAINTENANCE f. Remove hardware securing the lower boom

pivot pin. Using a suitable brass drift and ham-
mer, remove pin from the turntable.
g. Using all applicable safety precautions, carefully
IF PERFORMING MAINTENANCE ON THE BOOM, DO NOT USE A lift boom assembly clear of turntable and lower
LIFTING DEVICE TO LIFT THE BOOMS UNLESSTHE HOLDING to ground or suitable supported work surface.
VALVES HAVE BEEN REMOVED FIRST. FAILURE TO DO SO WILL
RESULT IN SEVERE DAMAGE TO THE BOOM. Disassembly of the Main Boom
1. Loosen bolts on aft end of fly boom wear pads and
Removal of the Boom Assembly remove shims.
1. Remove the platform and platform support as fol- 2. Using a portable power source, attach hose to tele-
lows: scope cylinder port block. Using all applicable
a. Disconnect electrical cable from control con- safety precautions, activate hydraulic system and
sole. extend cylinder to gain access to cylinder rod retain-
ing pin. Shut down hydraulic system.
b. Tag and disconnect the hydraulic lines running
to the rotate cylinders. Cap the hydraulic lines 3. Carefully disconnect hydraulic hose from retract port
and ports. of cylinder. There will be initial weeping of hydraulic
fluid which can be caught in a suitable container.
c. Using an overhead crane or suitable lifting
After initial discharge, there should be no further
device, use nylon support straps to support the
leakage from the retract port.
platform/support, and jib if applicable.
4. Remove hardware securing telescope cylinder to
NOTE: When removing the retaining pin from the rod end of the fly boom section, then remove pin from fly.
the level cylinder, make sure the cylinder is properly
5. Remove hardware securing telescope cylinder to
supported.
the base boom section.
d. Remove bolts and keeper pins that secures the
retaining pins. Using a suitable brass drift and
hammer, remove the retaining pins from the plat- WHEN REMOVING TELESCOPE CYLINDER FROM BOOM SEC-
form support. TIONS. CARE SHOULD BE TAKEN NOT TO LEAVE CYLINDER REST
2. Remove the boom from the turntable as follows: ON POWERTRACK WHICH COULD CAUSE DAMAGE TO POWER-
a. Disconnect wiring harness from ground control TRACK.
harness connector.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-

ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON-
TAMINANTS INTO SYSTEM.
b. Tag and disconnect hydraulic lines from boom

to control valve. Use a suitable container to
retain any residual hydraulic fluid. Cap all
hydraulic lines and ports.
c. Using a suitable lifting equipment, adequately
support boom weight along entire length.
d. Remove the bolts and keeper pins securing the
lift cylinder pivot pin. Using a suitable brass drift
and hammer, remove the pivot pin from the
lower boom.
e. Remove hardware securing the level link pivot
pin. Using a suitable brass drift and hammer,
remove the pin from the level link and turntable.
3120772 – JLG Lift – 4-1

4
1
12
7
8 10 11
1. Master Cylinder 5. Fly Boom 9. Lower Boom

2. Boom Lift 6. Mid Link 10. Tower Lift Cylinder
3. Level Cylinder 7. Mid Boom 11. Lower Upright
4. Base Boom 8. Lower Link 12. Upper Upright
Figure 4-1. Boom Assembly
4-2 – JLG Lift – 3120772

11
1
3
1
3
3 16
6
3
1
3 1
7
3
3 13
3 14
15
1 8
10
1
3 3
14
1
3
1
3 3
9
1
6
4 14 3
7
12
1. Loctite #242 6. Mid Link 11. Upper Upright

2. Bumper 7. Mid Boom 12. Boom Rest
3. Composite Bearing 8. Lower Link 13. Lower Upright
4. Channel 9. Lower Boom 14. Composite Bearing
5. Tower Lift Cylinder 10. Timing Link
Figure 4-2. Tower Boom Assembly
3120772 – JLG Lift – 4-3

6. Using a suitable lifting device, remove telescope cyl- 6. Using suitable lifting equipment, slide fly boom sec-
inder from boom sections. tion out to gain access to telescope cylinder attach
7. Using a piece of tape, mark the length of hoses and pin hole.
wires from front of fly boom and bottom of base 7. Measure the distance between the telescope cylin-
boom for reassembly. der port block attach point on base boom section
8. Remove hardware securing the front wear pads on and the attach point on fly boom section.
base boom section, remove wear pads. 8. Connect a suitable auxiliary hydraulic power source
9. Remove hardware securing the power track to the to the telescope cylinder port block.
aft end of the fly boom section. 9. Extend the telescope cylinder the distance of the
10. Using a suitable lifting device, remove fly boom from two attach points.
boom section. 10. Secure the sling and lifting device at the telescope
11. Remove hydraulic lines and electrical cables from cylinder’s approximate center of gravity, and lift the
power track. cylinder to the aft end of the boom assembly.
12. Remove hardware securing power track to the base

boom section. Remove power track.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
Inspection CARE MUST BE TAKEN NOT TO DAMAGE THE POWER TRACK
ASSEMBLY.
1. Inspect all boom pivot pins for wear, scoring or other
damage, and for tapering or ovality. Replace pins as 11. Slowly slide the telescope cylinder into boom
necessary. assembly, align rod end with attach point in fly sec-
2. Inspect lift cylinder pins for wear, scoring or other tion. Insert pin and secure with retaining ring.
damage, and for tapering or ovality. Ensure pin sur- 12. Align bolt holes at aft end of base boom section with
faces are protected prior to installation. Replace pins telescope cylinder port block. Secure telescope cyl-
as necessary. inder with hardware.
3. Inspect telescope cylinder rod attach pin for wear, 13. Install wear pads at end of base boom section.
scoring or other damage. Replace pin as necessary. Using shims, adjust the adjustable wear pads to
4. Inspect inner diameter of boom pivot bushings for zero clearance. Adjust pads alternately side to side,
scoring, distortion, wear or other damage. Replace so that fly boom section is centered in base boom
bushings as necessary. section.
5. Inspect wear pads for wear. 14. Retract boom section fully. Using shims, adjust wear
pads at aft end of boom section to zero clearance.
6. Inspect all threaded components for damage such
Adjust pads alternately side to side, so that fly boom
as stretching, thread deformation, or twisting.
section is centered in base boom section.
Replace as necessary.
15. Disconnect auxiliary power source from telescope
7. Inspect structural units of boom assembly for bend-
cylinder.
ing, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
Assembly of the Main Boom

1. Install power track to the attach point on the base
boom section. Secure power track with the attaching
hardware.
2. Install hydraulic lines and electrical cables into the
power track.
3. Install wear pads to the aft end of the fly section.
4. Using suitable lifting equipment, slide fly section into
the base section until power track attach point aligns
with holes in side of base section.
5. Attach the power track to the aft end of fly boom
section. Secure power track with the attaching hard-
ware.
4-4 – JLG Lift – 3120772

Installation of the Boom Assembly 4.2 WEAR PADS

1. Using suitable lifting equipment, position boom 1. Shim up wear pads until snug to adjacent surface.
assembly on turntable so that boom pivot holes in
both boom and turntable are aligned. 2. Bolt into threaded insert of wear pad.
2. Install boom pivot pin, ensuring that location of the 3. Replace wear pads when worn to thickness of 9/16”.
hole in pivot pin aligns with attach point on upright.
3. Using all applicable safety precautions, operate lift-
ing equipment in order to position boom lift cylinder
and level link so that holes in cylinder rod end and
level link are aligned with the one in the turntable.
Insert cylinder pins.
4. If necessary, gently tap pins into position with a soft
headed mallet, ensuring that attach holes in pins are
aligned with attach holes in boom structure. Secure
with hardware.
5. Connect all hosing and wiring.
6. Install the platform, and jib if applicable, to the boom
Figure 4-3. Location of wear Pads
assembly.
7. Connect all hosing and wiring at platform control
station.
8. Using all safety precautions, operate machine sys-
tems and extend and retract boom for four or five
cycles.
9. Shut down machine systems and check for leakage.
3120772 – JLG Lift – 4-5

4.3 ARTICULATING JIB (AJ/AJP) 4.4 TILT INDICATOR SWITCH LEVELING

Removal
PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI-
1. Place the Jib in a horizontal position and support the
MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION
complete assembly with adequate blocking.
AND ADJUSTMENT OF SWITCH.
2. Remove the Platform as follows:
a. Disconnect the electrical connectors going into 1. Check chassis out of level indicator light located on
the platform control box. the platform control console by driving, with the
machine in level position, up a suitable ramp of at
b. Remove the bolts, nuts, and washers connect- least 6° slope. Check the out of level alarm, with the
ing the platform basket to the platform support. machine on the ramp, raise the upper boom until it
c. Using a suitable lifting device, remove the plat- is parallel with the chassis. DO NOT RAISE ABOVE
form basket from the platform support. THE PARALLEL POSITION. If the light does not illu-
3. Tag and disconnect the hydraulic lines running to minate, return the machine to a level surface, shut
the Jib. Use a suitable container to collect any resid- down the machine, and contact a qualified techni-
ual fluid. Cap the hydraulic lines and ports. cian before resuming operation.
4. Remove the hardware securing the Jib pivot pin at
the boom. Using a suitable brass drift and hammer, 4.5 FOOTSWITCH ADJUSTMENT
remove the pin from the fly boom. Use a suitable lift-
ing device and remove the Jib. Adjust switch so that functions will operate when pedal is
at center of travel. If switch operates within last 1/4 inch
(6.35 mm) of travel, top or bottom, it should be adjusted.
4.6 BOOM LIMIT SWITCHES

Refer to Figure 4-7., Boom Limit Switches for adjustments
to be made of the two Limit Switches which bolt in place
on the upright.
4-6 – JLG Lift – 3120772

Figure 4-4. Jib - E300AJ
Figure 4-5. Jib - E300AJP
3120772 – JLG Lift – 4-7

NOTE: If any rotator bolts are replaced, all bolts

A,B,D on the rotator should be retorqued.
C,D
A Torque to 50 ft.lbs. (68 Nm)

B Loctite #242
C Torque 250-270 ft. lbs. (339-366 Nm)
D Check torque every 150 hours of operation
Figure 4-6. Platform Support Torque Values
4-8 – JLG Lift – 3120772

DETAIL A
NOTE: UPPER BOOM ANGLE TO BE 1° BELOW

HORIZONTAL TO 3° ABOVE HORIZONTAL
TO ACTIVATE SWITCH. UPPER BOOM
ANGLE TO BE 1° TO 4° BELOW HORIZONTAL
TO RESET SWITCH
NOTE: LOWER BOOM ANGLE TO BE 1°
TO 5° ABOVE HORIZONTAL TO ACTIVATE
SWITCH. LOWER BOOM ANGLE TO BE 0°
TO 5° BELOW HORIZONTAL TO
RESET SWITCH
SEE DETAIL A
Figure 4-7. Boom Limit Switches
3120772 – JLG Lift – 4-9

NOTES:
4-10 – JLG Lift – 3120772

SECTION 5. HYDRAULICS
5.1 LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in
HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com-
When assembling connectors in the hydraulic that use o- pletely saturated.
ring fittings, it is necessary to lubricate all fittings with
hydraulic oil prior to assembly. To lubricate the fittings, use
one of the following procedures.
NOTE: All O-ring fittings must be pre-lubricated with hydrau-

lic oil prior to assembly.
Cup and Brush

The following is needed to correctly oil the o-ring in this
manner:
• A small container for hydraulic oil

• Small paint brush 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring
is coated with hydraulic oil.
1. Hold the fitting in one hand while using the brush

with the other hand to dip into the container.
Remove excess hydraulic oil from the brush so an
even film of oil is applied on the o-ring.
3120772 – JLG Lift – 5-1

Dip Method Spray Method

NOTE: This method works best with Face Seal o-rings, but This method requires a pump or trigger spray bottle.
will work for all o-ring fitting types.
1. Fill the spray bottle with hydraulic oil.
The following is needed to correctly oil the o-ring in this 2. Hold the fitting over a suitable catch can.
manner:
3. Spray the entire o-ring surface with a medium coat
• A small leak proof container of oil.
• Sponge cut to fit inside the container

• A small amount of hydraulic oil to saturate the sponge.
1. Place the sponge inside the container and add
hydraulic oil to the sponge until it is fully saturated.
2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and
drip from the bottom of the fitting. This should signify
an even coating of oil on the fitting.
Brush-on Method
This method requires a sealed bottle brush.
1. Fill the bottle with hydraulic oil.

2. Using slight pressure to the body of the spray bottle,
invert the bottle so the brush end is in the downward
position.
3. Brush hydraulic oil on the entire o-ring, applying an
3. O-ring Boss type fittings will require more pressure even coat of oil.
in able to immerse more of the fitting into the satu-
rated sponge. This will also cause more oil to be dis-
persed from the sponge.
5-2 – JLG Lift – 3120772

5.2 CYLINDERS - THEORY OF OPERATION 6. Activate hydraulic system and activate cylinder
retract function. Check extend port for leakage.
Systems Incorporating Double Acting 7. If extend port leakage is less than 6-8 drops per
minute, carefully reconnect hose to extend port,
Cylinders then activate cylinder through one complete cycle
Upper Boom Lift, Lower Boom Lift, Telescope, Slave, and check for leaks. If leakage continues at a rate of
Master, Steer Cylinder. 6-8 drops per minute or more, cylinder repairs must
A double acting cylinder is one that requires oil flow to be made.
operate the cylinder rod in both directions. Directing oil
(by actuating the corresponding control valve to the pis- Cylinders With Single Counterbalance Valve
ton side of the cylinder) forces the piston to travel toward (Upper Lift Cylinder)
the rod end of the barrel, extending the cylinder rod (pis-
ton attached to rod). When the oil flow is stopped, move-
ment of the rod will stop. By directing oil to the rod side of
the cylinder, the piston will be forced in the opposite direc- OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
tion and the cylinder rod will retract. ONLY.
Holding valves are used in the Lift circuits to prevent
1. Using all applicable safety precautions, activate
retraction of the cylinder rod should a hydraulic line rup-
hydraulic system.
ture or leak develop between the cylinder and its related
control valve.
WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE

5.3 CYLINDER CHECKING PROCEDURES THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. IF
NOTE: Cylinder checks must be performed any time a cylin- WORKING ON TOWER BOOM LIFT CYLINDER, RAISE LOWER LIFT
der component is replaced or when improper sys- HALFWAY, FULLY ELEVATE UPPER BOOM AND ATTACH OVER-
tem operation is suspected. HEA D CR ANE T O THE UPRI GHT FOR S UPPOR T, LE AVING
APPROXIMATELY 1 INCH (2.54 CM) OF SLACK IN CHAIN OR
Cylinder Without Counterbalance Valves SLING FOR TEST PURPOSES.
(Steer and Master)
2. After completing the above, shut down hydraulic
1. Using all applicable safety precautions, activate system and allow machine to sit for 10-15 minutes.
hydraulic system and fully extend cylinder to be This is done to relieve pressure in the hydraulic
checked. Shut down hydraulic system. lines. Carefully remove hydraulic hoses from appro-
2. Carefully disconnect hydraulic hose from retract port priate cylinder port block.
of cylinder. There will be initial weeping of hydraulic 3. There will be initial weeping of hydraulic fluid, which
fluid which can be caught in a suitable container. can be caught in a suitable container. After the initial
After initial discharge, there should be no further discharge, there should not be any further leakage
leakage from the retract port. from the ports. If leakage continues at a rate of 6-8
3. Activate hydraulic system, and activate cylinder drops per minute or more, the following cylinder
extend function. repairs must be made. If the retract port is leaking,
the piston is leaking, the piston seals are defective
4. If cylinder retract port leakage is less than 6-8 drops and must be replaced. If the extend port is leaking,
per minute, carefully reconnect hose to retract port the counterbalance is defective and must be
and retract cylinder. If leakage continues at a rate of replaced.
6-8 drops per minute or more, cylinder repairs must
be made. 4. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
5. With cylinder fully retracted, shut down motor and the appropriate ports.
carefully disconnect hydraulic hose from cylinder
extend port. 5. Remove boom prop/overhead crane, activate
hydraulic system and run cylinder through complete
cycle to check for leaks and operation.
3120772 – JLG Lift – 5-3

Cylinders With Dual Counterbalance Valve 4. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
(Lower Lift, Telescope, and Slave Cylinders) discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION repairs must be made. If the retract port is leaking,
ONLY. the piston is leaking, the piston seals are defective
and must be replaced. If the extend port is leaking,
1. Using all applicable safety precautions, activate the counterbalance is defective and must be
hydraulic system. replaced.
5. To check piston seals, carefully remove the counter-
balance valve from the retract port. After initial dis-
charge there should not be any further leakage from
WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE
the ports. If leakage occurs at a rate of 6-8 drops per
THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
minute or more, the piston seals are defective and
APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. must be replaced.
REFER TO FIG. 2-1. IF WORKING ON LOWER LIFT CYLINDER,
RAISE TOWER BOOM HALFWAY, AND ATTACH OVERHEAD CRANE 6. If no repairs are necessary or when repairs have
TO THE UPRIGHT FOR SUPPORT, LEAVING APPROXIMATELY 1 been made, carefully reconnect hydraulic hoses to
INCH (2.54 CM) OF SLACK IN CHAIN OR SLING FOR TEST PUR- the appropriate ports.
POSES. 7. Remove boom prop/overhead crane, activate
hydraulic system and run cylinder through complete
2. When working on the platform slave cylinder, stroke cycle to check for leaks and operation.
platform slave level cylinder forward until platform
sits at a 45 degree angle.
3. After completing the above, shut down hydraulic
system and allow machine to sit for 10-15 minutes.
This is done to relieve pressure in the hydraulic
lines. Carefully remove hydraulic hoses from appro-
priate cylinder port block.
5-4 – JLG Lift – 3120772

Figure 5-1. Boom Positioning and Support, Cylinder Repair
5.4 CYLINDER REPAIR

NOTE: The following are general procedures that apply to DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
all of the cylinders on this machine. Procedures that RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
apply to a specific cylinder will be so noted.
2. Operate the hydraulic power source and extend the
Disassembly cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if appli-
cable.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A 3. If applicable, remove the cartridge-type holding
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. valve and fittings from the cylinder port block. Dis-
card o-rings.
1. Connect a suitable auxiliary hydraulic power source 4. Place the cylinder barrel into a suitable holding fix-
to the cylinder port block fitting. ture.
3120772 – JLG Lift – 5-5

Figure 5-2. Cylinder Barrel Support

Figure 5-4. Cylinder Rod Support
5. Mark cylinder head and barrel with a center punch
for easy realignment. Using an allen wrench, loosen 9. Using suitable protection, clamp the cylinder rod in
the cylinder head retainer cap screws, and remove a vise or similar holding fixture as close to the piston
cap screws from cylinder barrel. as possible.
10. Loosen and remove the cap screw(s), if applicable,
which attach the tapered bushing to the piston.
11. Insert the cap screw(s) in the threaded holes in the
outer piece of the tapered bushing. Progressively
tighten the cap screw(s) until the bushing is loose
on the piston.
12. Remove the bushing from the piston.
Figure 5-3. Capscrew Removal
NOTE: Steps 6 applies only to the lower lift and telescope

cylinders.
6. Using a spanner wrench, loosen the end cap or

head retainer, and remove from cylinder barrel.
7. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
Figure 5-5. Tapered Bushing Removal

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL- 13. Screw the piston CCW, by hand, and remove the
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF- piston from cylinder rod.
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES. 14. Remove and discard the piston o-rings, seal rings,
and backup rings.
8. With the barrel clamped securely, apply pressure to 15. Remove piston spacer, if applicable, from the rod.
the rod pulling device and carefully withdraw the 16. Remove the rod from the holding fixture. Remove
complete rod assembly from the cylinder barrel. the cylinder head gland and retainer plate, if applica-
ble. Discard the o-rings, back-up rings, rod seals,
and wiper seals.
5-6 – JLG Lift – 3120772

Cleaning and Inspection 13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
1. Clean all parts thoroughly in an approved cleaning as necessary.
solvent. a. Thoroughly clean hole, (steel bushing) of burrs,
2. Inspect the cylinder rod for scoring, tapering, ovality, dirt etc. to facilitate bearing installation.
or other damage. If necessary, dress rod with b. Inspect steel bushing for wear or other damage.
Scotch Brite or equivalent. Replace rod if necessary. If steel bushing is worn or damaged, rod/barrel
3. Inspect threaded portion of rod for excessive dam- must be replaced.
age. Dress threads as necessary. c. Lubricate inside of the steel bushing with WD40
4. Inspect inner surface of cylinder barrel tube for scor- prior to bearing installation.
ing or other damage. Check inside diameter for d. Using an arbor of the correct size, carefully
tapering or ovality. Replace if necessary. press the bearing into steel bushing.
5. Inspect threaded portion of barrel for damage. Dress NOTE: Install pin into the Gar-Max bearing dry. Lubrication is
threads as necessary. not required with nickel plated pins and bearings.
6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec-
essary.
9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.
Figure 5-6. Gar-Max Bearing installation
10. Inspect threaded portion of head for damage. Dress
threads as necessary.
14. Inspect travel limiting collar or spacer for burrs and
11. Inspect seal and o-ring grooves in head for burrs sharp edges. If necessary, dress inside diameter
and sharp edges. Dress applicable surfaces as nec- surface with Scotch Brite or equivalent.
essary.
15. If applicable, inspect port block fittings and holding
12. Inspect cylinder head outside diameter for scoring valve. Replace as necessary.
or other damage and ovality and tapering. Replace
as necessary. 16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
3120772 – JLG Lift – 5-7

7
27
13
13
10
6
18
19
25
19
18
5
14
16
20
22
17
9
21 23
3*,4*,24
12
1,3,26
11
*Prior to S/N 0300106517 8
1. Loctite #242 7. Composite Bearing 13. O-ring Plug 18. Seal Ring 23. Seal
2. Not Used 8. Composite Bearing 14. Piston 19. Wear Ring 24. Wiper
3. Primer #7471 9. Cylinder Head 15. Not Used 20. Wear Ring 25. Seal
4. Loctite RC 609 10. Barrel 16. Backup Ring 21. O-ring 26. Bolt
5. Bolt 11. Rod 17. Backup Ring 22. O-ring 27. Cartridge Valve
6. Tapered Bushing 12. Washer Ring
Figure 5-7. Jib Cylinder
5-8 – JLG Lift – 3120772

5
21
3
1
22
8
4
12
20
10
20
12
14
15
14
13
16
19
6
9 18
17
1
23
2
1. Loctite #242 6. Head 11. Not Used 16. O-ring 21. Counterbalance Valve
2. Primer #7471 7. Rod 12. Lock Ring 17. Wiper 22. Counterbalance Valve
3. Bolt 8. Barrel 13. Wear Ring 18. Seal 23. Bolt
4. Tapered Bushing 9. Ring Washer 14. Backup Ring 19. Backup Ring
5. Composite 10. Piston 15. O-ring 20. Seal
Bushing
Figure 5-8. Level Cylinder
3120772 – JLG Lift – 5-9

7
1
2
23
17 22
18
17
8
3
12
21
10
14
11
5
19 13
1 16
20 15
23
1. Loctite #242 6. Rod 11. Backup Ring 16. Seal 21. Tube Spacer
2. Bolt 7. Barrel 12. Backup Ring 17. Wear Ring 22. Counterbalance Valve
3. Tapered Bushing 8. Piston 13. O-ring 18. Cap 23. Locking Primer
4. Composite Bushing 9. Not Used 14. O-ring 19. Ring Washer
5. Head 10. Wear Ring 15. Wiper 20. Bolt
Figure 5-9. Main Boom Lift Cylinder
5-10 – JLG Lift – 3120772

1. O-ring 6. O-ring 11. Setscrew 16. Valve Cartridge 21. Head

2. O-ring 7. Seal 12. Setscrew 17. Bushing 22. Locknut
3. Backup Ring 8. Wear Ring 13. Nylon Plug 18. Barrel
4. Seal 9. Wear Ring 14. Plug 19. Rod
5. Wiper 10. Not Used 15. Plug 20. Piston
Figure 5-10. Tower Boom Lift Cylinder
3120772 – JLG Lift – 5-11

5
9
3
1
2
4
12
20
6
20
12
14
15
14
16
19
13
8
18
7 17
1
2
21
10
1. Loctite #242 7. Ring Washer 12. Lock Ring 17. Wiper

2. Locking Primer 8. Head 13. Wear Ring 18. Seal
3. Bolt 9. Barrel 14. Backup Ring 19. Backup Ring
4. Tapered Bushing 10. Rod 15. O-ring 20. Seal
5. Composite Bushing 11. Not Used 16. O-ring 21. Bolt
6. Piston
Figure 5-11. Master Cylinder
5-12 – JLG Lift – 3120772

5A
1
2
11
14
3
8
9
10 13
12
1. Locknut 5. Barrel 9. Backup Ring 13. Wiper

2. Piston 6. Rod 10. Retaining Ring 14. Wear Ring
3. Piston Seal 7. Guide 11. Seal
4. O-ring 8. O-ring 12. Nut
Figure 5-12. Steer Cylinder
3120772 – JLG Lift – 5-13

29
28
27
12
6
30
10
13
31
22
7 31
16 5
25
16
15
18
19 14
18
26
21
20
32
17
9
24
23
8
11
1. Loctite #242 8. Cap 15. Piston 21. Setscrew 27. Valve Assembly
2. Not Used 9. Head 16. Wear Ring 22. Bolt 28. Valve Cartridge
3. Locking Primer 10. Barrel 17. Wear Ring 23. Wiper 29. Valve Cartridge
4. Loctite 11. Rod 18. Backup Ring 24. Seal 30. Flatwasher
5. Bolt 12. O-ring 19. O-ring 25. Teflon Seal 31. Flatwasher
6. Bolt 13. Locknut 20. O-ring 26. Tube Spacer 32. Backup Ring
7. Tapered Bushing 14. Pad
Figure 5-13. Telescope Cylinder
5-14 – JLG Lift – 3120772

Assembly
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components

prior to assembly.
1. A special tool is used to install a new rod seal into

the applicable cylinder head gland groove.
Figure 5-15. Wiper Seal Installation
3. Place a new o-ring and back-up seal in the applica-

ble outside diameter groove of the cylinder head.
4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.
Figure 5-14. Rod Seal Installation
WHEN INSTALLING “POLY-PAK” PISTON SEALS, ENSURE SEALS

ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA-
TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL Figure 5-16. Installation of Head Seal Kit
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION. 5. Carefully slide the piston spacer on the rod.
6. If applicable, correctly place new o-ring in the inner
2. Use a soft mallet to tap a new wiper seal into the piston diameter groove. (The backup ring side fac-
applicable cylinder head gland groove. Install a new ing the O-ring is grooved.)
wear ring into the applicable cylinder head gland
7. If applicable, correctly place new seals and guide
groove.
lock rings in the outer piston diameter groove. (A
tube, with I.D. slightly larger than the O.D.of the pis-
ton is recommended to install the solid seal.)
NOTE: The backup rings for the solid seal have a radius on
one side. This side faces the solid seal. The split of
seals and backup rings are to be positioned so as
not to be in alignment with each other.
3120772 – JLG Lift – 5-15

Figure 5-18. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 5-1,
Cylinder Head and Tapered Bushing Torque Specifi-
cations.)
13. After the screws have been torqued, tap the bushing
with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4” in dia.) as follows;
Figure 5-17. Piston Seal Kit Installation a. Place the brass shaft against the tapered bush-
ing on the spaces between the capscrews.
8. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to piston as b. Tap each space once; this means the tapered
possible. bushing is tapped three times as there are three
spaces between the capscrews.
9. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.
10. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.
NOTE: When installing the tapered bushing, piston and mat-

ing end of rod must be free of oil.
WHEN REBUILDING THE STEER, TOWER LIFT, LEVEL CYLINDER,

UPPER LIFT CYLINDER, OR E.A.R. CYLINDERS, APPLY LOCTITE
#242 TO TAPERED BUSHING BOLTS, THEN TIGHTEN SECURELY.
(SEE TABLE 5-1 ANDTABLE 5-2 TORQUE SPECIFICATIONS).
11. Assemble the tapered bushing loosely into the pis- Figure 5-19. Seating the Tapered Bearing
ton and insert JLG capscrews (not vender cap-
screws) through the drilled holes in the bushing and
14. Retorque the capscrews evenly and progressively in
into the tapped holes in the piston using loctite
rotation to the specified torque value. (See Table 5-1,
#242.
Cylinder Head and Tapered Bushing Torque Specifi-
cations.)
15. Remove the cylinder rod from the holding fixture.
16. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston. (see
Table 5-17., Piston Seal Kit Installation)
5-16 – JLG Lift – 3120772

IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON

THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER
A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS
TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING
ROD.
Table 5-1. Cylinder Head and Tapered Bushing Torque

Specifications
Figure 5-20. Poly-Pak Piston Seal Installation
Head Torque Value Tapered Bushing
17. Position the cylinder barrel in a suitable holding fix- Description
(Wet) Torque Value (Wet)
ture.
Upper Lift Cylinder 44 ft. lbs 9ft. lbs.
(61 Nm) (12 Nm)
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL-
Telescope Cylinder 44 ft. lbs 9ft. lbs.
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
(61 Nm (12 Nm)
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES. Level Cylinder 30 ft. lbs. 5 ft. lbs.
(41 Nm) (7 Nm)
18. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the Master Cylinder 30 ft. lbs. 5 ft. lbs.
barrel cylinder. Ensure that the piston loading o-ring (41 Nm) (7Nm)
and seal ring are not damaged or dislodged.
E.A.R. Cylinder 30 ft. lbs. 5 ft. lbs.
19. Continue pushing the rod into the barrel until the cyl- (41 Nm) (7 Nm)
inder head gland can be inserted into the barrel cyl-
inder.
20. Secure the cylinder head gland using the washer
ring and socket head bolts. See Table 5-1 and Table Table 5-2. Holding Valve Torque Specifications
5-2).
Description Torque Value
SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

(41-48 Nm)
SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

(61-68 Nm)
SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

(204-217 Nm)
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.

(68-75 Nm)

(102-109 Nm)
Figure 5-21. Rod Assembly Installation
21. After the cylinder has been reassembled, the rod (136-149 Nm)
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
22. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Table 5-2 Holding Valve Torque
Specifications).
3120772 – JLG Lift – 5-17

5.5 CYLINDER REMOVAL AND Upper (Main) Boom Lift Cylinder Installation
INSTALLATION NOTE: Coat I.D. of bushings with specified lubricant prior to
installing pins.
Upper (Main) Boom Lift Cylinder Removal
1. Install Lift Cylinder in place using suitable slings or
1. Place the machine on a flat and level surface. Place supports, aligning attach pin mounting holes on
the Upper Boom in a horizontal position. Place upright.
Tower halfway (approx. 37 degrees). Shut down
machine and prop boom. 2. Using a suitable drift, drive the barrel end attach pin
#2 through the mounting holes in the lift cylinder
2. Tag, disconnect and cap the upper boom lift cylinder and upright. Secure in place with pin retaining hard-
hydraulic lines and ports. ware.
3. Remove the hardware securing the cylinder rod 3. Remove cylinder port plugs and hydraulic line caps
attach pin #1 to the boom. Using a suitable brass and correctly attach lines to cylinder ports.
drift, drive out the cylinder rod attach pin #1.
4. With function speed switch at its slowest setting,
extend the cylinder rod until attach pin hole aligns
with those in boom. Using a suitable drift, drive the
cylinder rod attach pin #1 through the aligned
holes. Secure the pin in place with pin retaining
hardware.
5. Cycle cylinder completely to check for proper func-
tioning. Place boom in stowed position. Check
hydraulic fluid level and adjust accordingly.
Lower Lift Cylinder Removal

1. Place machine on flat and level surface. Place the
Upper Boom in a horizontal position. Raise the
Tower halfway. See Figure 2-1. Support Upper Boom
with a prop. Support upright with an overhead
crane.
2. Using slings, restrain the Tower lift cylinder.
3. Remove the hardware securing the cylinder rod
attach pin #5 to the boom. Using an appropriate
brass drift, drive out the cylinder rod attach pin #5.
Figure 5-22. Upper Boom Lift Cylinder Removal
4. Secure the cylinder with suitable slings or supports
as required. Remove the hardware securing the bar-
rel end attach pin #2. Using a suitable brass drift,
drive out the barrel end attach pin #2.
5. Remove the cylinder from the boom and place in a
suitable work area.
5-18 – JLG Lift – 3120772

5. Remove boom prop and overhead crane. Take the

lift cylinder through one complete cycle to assure
correct functioning. Place boom in stowed position.
Check hydraulic fluid and adjust accordingly.
Upper Boom Telescope Cylinder Removal

1. Place machine on flat and level surface, with Upper
Boom in the horizontal position. Extend Upper
Boom until fly attach pin #1 is accessible on fly.
2. Support Upper Boom basket end with a prop. Sup-
port Upper Upright end with an overhead crane.
5
3. Tag, disconnect hydraulic lines to telescope cylinder.
Use suitable container to retain any residual hydrau-
6 lic fluid. Cap hydraulic lines and ports.
4. Remove the retaining rings that retain the telescope
cylinder rod to the fly boom.
5. Using a suitable brass drift, carefully drive the tele-
scope cylinder rod pin #1 from the fly boom.
6. Remove the four (4) bolts securing the telescope
cylinder barrel end to the base boom.
NOTE: Care should be taken when removing the telescope

cylinder, do not leave cylinder rest on powertrack
which could cause damage to powertrack.
7. Using a suitable brass drift, carefully drive the tele-

scope cylinder pin from the base boom.
Figure 5-23. Lower Lift Cylinder Removal
8. Attach a suitable sling to the telescope cylinder.
4. Tag, disconnect and cap the lift cylinder hydraulic Using a suitable lifting device attached to the sling
lines and ports. carefully pull the telescope cylinder from the boom
5. Remove the hardware securing the barrel end attach assembly.
pin #6 to the boom. Using an appropriate brass 9. Using another lifting device, support the rod end of
drift, drive out the cylinder barrel pin #6. the cylinder and remove the cylinder from the boom
6. Carefully remove cylinder from boom. Place in a assembly.
suitable work area. 10. Carefully lift the cylinder clear of the boom assembly
and lower to the ground or suitably supported work
Lower Lift Cylinder Installation area.
NOTE: Coat I.D. of bushings with specified lubricant prior to
installing pins.
1. With the Tower positioned and supported as in Fig-

ure 5-1., place cylinder in position and secure in
place using slings.
2. Install the cylinder barrel pin #6, being sure to align
the hole in the cylinder barrel pin with the retaining
pin screw hole. When holes align, install hardware.
3. Correctly install hydraulic lines to cylinder as previ-
ously tagged. Extend cylinder rod slowly until attach
pin hole aligns with those in boom.
4. Using a suitable brass drift, drive the cylinder rod
attach pin #5 through the aligned holes. Secure the
pin in place using retaining hardware.
3120772 – JLG Lift – 5-19

Upper Boom Telescope Cylinder Installation 5.6 LOWER LIFT CYLINDER BLEEDING
1. Attach a hydraulic power supply to the telescope PROCEDURE
cylinder ports. Using suitable supports or lifting
NOTE: Bleeding procedure should only be necessary if
devices at each end of the cylinder, extend the rod
rebuilding or replacing lift cylinder.
so that the cylinder pin attach holes are the same
distance apart as the boom pin attach holes. 1. Check oil level in the hydraulic oil tank (all booms
must be retracted).
2. Lay an oil drip pan under the rod end port block and
crack bleeder open from the fitting in the port block.
3. From the platform, turn the speed control knob to
the slow position.
4. Lift up very slowly. This will force any air out of the
circuit. If the lower boom is not extending, turn the
speed control up very slowly until the lower boom
starts to move.
5. Raise the Tower boom approx. 1 foot (30.5 cm), then
close bleeder while the boom is still moving.
6. Lift down all the way.
7. Repeat this procedure until all air has been purged
from the circuit. Re-check the hydraulic oil level.
To test, cycle the lower lift function 3-4 times to see if both
cylinders stop at the same time when fully extended.
Figure 5-24. Upper Telescope Cylinder Removal
2. Using suitable lifting equipment, carefully lower the

cylinder to the boom assembly.
3. Using another lifting device, support the rod end of
the cylinder and install the cylinder into the boom
assembly.
4. Remove lifting devices from the telescope cylinder.
5. Carefully install the telescope cylinder rod pin #1
through the fly boom and secure it with the retaining
rings.
6. Carefully install the telescope cylinder barrel end to
base, securing cylinder to the base boom with four
(4) bolts and hardware.
7. Remove applicable hydraulic line and port caps and
correctly connect the hydraulic lines to the tele-
scope cylinder. Ensure all hoses are correctly
routed.
8. Remove boom prop and overhead crane. Activate
hydraulic system.
9. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
10. Check fluid level of hydraulic tank and add as neces-
sary.
5-20 – JLG Lift – 3120772

5.7 PRESSURE SETTINGS Platform Level Up Relief

Cold temperatures have a significant impact on pressure 1. On machines prior to S/N 0300063313, install the
readings.JLG Industries Inc. recommends operating the pressure gauge at the “G” port on Main Control
machine until hydraulic system has warmed to normal valve, activate and bottom out Platform Level Up.
operating temperatures prior to checking pressures. We
also recommend using a calibrated gauge. Pressure read- On machines S/N 0300063313 to present, install the
ings are acceptable if within +/- 5% of specified pres- pressure gauge at the "B2" port on the back of the
sures. Main Control Valve, activate and bottom out Platform
Level Up.
Main Relief at Pump
1. Install pressure gauge at port “G” on Steer/Brake
valve.
2. Activate and bottom out either Upper or Lower Lift
Up. Adjust Main Relief, (A/AJ) and (AJP), to value in
the pressure settings table.
Upper Lift Down Relief

1. With pressure gauge at “G” port on Main Control
valve, activate and bottom out Upper Lift Down.
2. Adjust Upper Lift Relief to value in the pressure set- LC LR
tings table.
T1
Lower Lift Down Relief LL LU
1. With pressure gauge at “G” port on Main Control

valve, activate and bottom out Mid/Lower Lift Down. P R
2. Adjust Lower Lift Relief to value in the pressure set-

tings table. TR TC
Swing Relief L
1. With pressure gauge at “G” port on Main Control T2

R2 R1
valve, activate and bottom out Swing function in
B2
either direction.
B1 17
2. Adjust Swing Relief to value in the pressure settings
table. S2
S1
Telescope In Relief
1. With pressure gauge at “G” port on Main Control 2. Adjust Platform Level Up Relief to value in the pres-
valve, activate and bottom out Telescope In. sure settings table.
2. Adjust the Telescope In Relief (A/AJ), to value in the

pressure settings table.
3120772 – JLG Lift – 5-21

Platform Level Down Relief Steer Relief

1. On machines prior to S/N 0300063313, install the 1. With pressure gauge at “G” port on Steer/Brake
pressure gauge at the “G” port on Main Control valve, activate and bottom out Steer Left or Right.
valve, activate and bottom out Platform Level Down.
2. Adjust Steer Relief to value in the pressure settings
table.
On machines S/N 0300063313 to present, install the
pressure gauge at the "B1" port on the back of the 3. Shut down hydraulic system and remove pressure
Main Control Valve, activate and bottom out Platform gauge.
Level Down.
Jib Lift (Up and Down) Relief
1. Install the pressure gauge at the at the "G" port on
the Main Control valve, activate and bottom out jib
up or down.
2. Adjust the Jib LIft pressure to the value given in the
Jib Swing Relief

1. Install the pressure gauge at the at the "G" port on
the Main Control valve, activate and bottom out jib
LC LR swing left or right.
2. Adjust the Jib Swing pressure to the value given in
T1
the pressure settings table.
LL LU
Table 5-3. Pressure Settings - Prior to S/N 0300063313

P R
Circuit PSI Bar
TR TC Main Control Valve

L
T2 Lower Lift Down Relief 1350 93

R2 R1
B2 Telescope In Relief (A/AJ) 2150 148
B1 17 Telescope In Relief (AJP) 3000 207
S2 Platform Level Up Relief 1500 103

S1

2. Adjust Platform Level Down Relief to value in the Swing Relief 1500 103
Steer/Brake Valve
Main Relief (AJP) 3200 221
Jib Valve
Jib Relief (Lift Up and Down) 1500 103
Jib Swing Relief 3000 207
5-22 – JLG Lift – 3120772

Table 5-4. Pressure Settings - S/N 0300063313 to 5.8 BRAKE/STEER VALVE HYDRAULIC
Present
FILTER REPLACEMENT
Circuit PSI Bar The Brake /Steer Valve is located on the turntable, under
the hydraulic tank. The hydraulic oil filter cartridge is in
Main Control Valve this valve and is recommended to be replaced every 6
months or sooner if the hydraulic controls become slow.
To replace, remove the 1-3/8 hex plug w/o-ring. The filter
Lower Lift Down Relief 1700 117 can now be pulled out. Only the oil in the filter will be
present. Insert the filter cartridge into valve to bottom.
Telescope Relief (A/AJ) 2150 148 Adjust the slotted head screw to be level with outside sur-
face of the valve, and replace the hex plug.
Telescope Relief (AJP) 3000 207
Platform Level Up Relief 3000 207
Swing Relief 1500 103
Steer/Brake Valve
Main Relief (AJP) 3200 221
Jib Valve
Jib Relief (Lift Up and Down) 1500 103
Jib Swing Relief 3000 207
Figure 5-25. Brake/Steer Valve Components
3120772 – JLG Lift – 5-23

STEER/BRAKE
VALVE
JIB VALVE
OR
JIB VALVE
MANUAL DESCENT
HANDLE
MAIN CONTROL
VALVE
Figure 5-26. Control Valve Installation
5-24 – JLG Lift – 3120772

Figure 5-27. Main Valve Components - Prior to S/N 0300063313
3120772 – JLG Lift – 5-25

20
11
2
19
3
16
12
4 24
18
8 1
17 13
10
14
5
15
21
9 7
6
1. Proportional Flow Regulator 8. Telescope In 15. Platform Level Forward
2. Bypass Unloading 9. Platform Level 16. Telescope Shuttle
3. Lower Lift 10. Rotator 17. P.O. Check - Platform Level Piston Side
4. Upper Lift 11. Lower Lift Down 18. P.O. Check - Platform Level Rod Side
5. Swing 12. Upper Lift Down 19. Manual Descent Knob
6. Swing Restrictor 13. Telescope 20. Manual Descent Pump
7. Telescope Out 14. Platform Level Back 21. Swing Relief Cartridge
Figure 5-28. Main Valve Components - S/N 0300063313 to Present
5-26 – JLG Lift – 3120772

Figure 5-29. HydraForce Cartridge Torque Value Chart
3120772 – JLG Lift – 5-27

NOTES:
5-28 – JLG Lift – 3120772

SECTION 6. JLG CONTROL SYSTEM
6.1 JLG CONTROL SYSTEM ANALYZER KIT CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC-
OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
INSTRUCTIONS MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
Introduction NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
The JLG designed Control System is a 48 volt based

WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON motor control unit installed on the boom lift.
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON-
TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUD- The JLG Control System has reduced the need for
ING OPTIONS. exposed terminal strips, diodes and trimpots and provides
simplicity in viewing and adjusting the various personality
settings for smooth control of: acceleration, deceleration,
creep and max.-speed for all boom, drive, and steering
functions.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
Figure 6-1. Control Module Location
3120772 – JLG Lift – 6-1

Figure 6-2. Power Module
6-2 – JLG Lift – 3120772

The upper lift, swing, and drive are controlled by individual To Connect the JLG Control System Analyzer
joysticks, with steering being controlled by a rocker switch
built into the top the drive joystick. To activate Drive, Lift, 1. Connect the four pin end of the cable supplied with
and Swing simply pull up on the slide lock location on the the analyzer, to the motor controller module located
joystick and move the handle into the direction desired. in the platform box or at the power module and con-
nect the remaining end of the cable to the analyzer.
The motor controller will control current output, as pro-
grammed for smooth operation and maximum cycle time. NOTE: The cable has a four pin connector at each end of
Ground control speeds for all boom functions can also be the cable; the cable cannot be connected back-
programmed into the motor controller. The motor control- wards.
ler also features an adjustable time limit for positive trac-
tion. 2. Power up the Control System by turning the lower
key to the platform or ground position and pulling
The JLG Control System controller has a built in LED to both emergency stop buttons on.
indicate any faults. The system stores recent faults which
may be accessed for troubleshooting. Optional equip- Using the Analyzer
ment includes an hour meter, beacon light, function cut-
out, and ground alarm. These options may be added later With the machine power on and the analyzer connected
but must be programmed into the motor controller when properly, the analyzer will display the following:
installed.
The Control System may be accessed by using a custom

designed, hand held analyzer (Analyzer, JLG part no.
1600244 & Cable, JLG part no. 1600633) which will dis- HELP:
play two lines of information at a time, by scrolling through PRESS ENTER
the program.
NOTE: Each module has a label with the JLG part number
and a serial number which contains a date code.
The following instructions are for using the hand held ana-
lyzer.
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
3120772 – JLG Lift – 6-3

The top level menus are as follows: menu. In some cases, such as DRIVE, the next level is the
HELP parameter or information to be changed. Refer to the flow
DIAGNOSTICS chart for what menus are available within the top level
ACTIVATE TEST menus. You may only view the personality settings for
ACCESS LEVEL selected menus while in access level 2. Remember, you
PERSONALITIES may always cancel a selected menu item by pressing the
MACHINE SETUP ESC. key.
LEVEL VEHICLE (level 1 only)
CALIBRATIONS (view only) Changing the Access Level of the Hand Held
If you press ENTER, at the HELP: PRESS ENTER display,
and a fault is present, the analyzer display will scroll the
Analyzer
fault across the screen. If there was no fault detected, the When the analyzer is first connected, you will be in access
display will read: HELP: EVERYTHING OK. If powered up
level 2 which enables you to only view most settings
at the ground station, the display will read: GROUND OK.
which cannot be changed until you enter a password to
If ENTER is pressed again, the display moves to the fol- advance to a lower level. This ensures that a setting can-
lowing display: not be accidentally altered. To change the access level,
the correct password must be entered. To enter the pass-
word, scroll to the ACCESS LEVEL menu. For example:
LOGGED HELP
1: STARTUP (2/1)
MENU:
ACCESS LEVEL 2
LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the sys- MENU:
tem has seen, if any are present. You may scroll through ACCESS LEVEL 2
the fault logs to view what the last 25 faults were. Use the
right and left arrow keys to scroll through the fault logs. To Press ENTER to select the ACCESS LEVEL menu.
return to the beginning, press ESC. two times. STARTUP
Using the UP or DOWN arrow keys, enter the first digit of
(2/1) indicates a power up.
the password, 3.
When a top level menu is selected, a new set of menu
items may be offered: for example: Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the pass-
DRIVE
word.
BOOM
SYSTEM Use the UP or DOWN arrow key to enter the second digit
DATALOG of the password which is 33271.
VERSIONS
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected
6-4 – JLG Lift – 3120772

Once the correct password is displayed, press ENTER. Adjusting Parameters Using the Hand Held
The access level should display the following, if the pass-
word was entered correctly: Analyzer
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
MENU:
ACCESS LEVEL 1
PERSONALITIES:
DRIVE ACCEL 1.0s
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings. PERSONALITIES:
DRIVE ACCEL 1.0s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular per-
sonality. If the value does not change when pressing the
up and down arrows, check the access level to ensure
you are at access level 1.
3120772 – JLG Lift – 6-5

Machine Setup There is a setting that JLG strongly recommends that you
do not change. This setting is so noted below:
When a machine digit item is selected, press the UP or ELEVATION CUTBACK
DOWN arrow keys to adjust its value, for example:
CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER-

FORMANCE OF YOUR MACHINE.
GROUND ALARM:
2=DRIVE
ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-

TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOM-
MENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
Table 6-1. Machine Setup Descriptions
MODEL NUMBER... Displays/adjusts machine model

NOTE: all personalities reset to default
when model number is altered
GROUND ALARM: TILT... Displays/adjusts tilt sensor function

2 = DRIVE
DRIVE CUTOUT... Displays/adjusts drive cutout switch
The effect of the machine digit value is displayed along presence/ function
with its value. The above display would be selected if the
FUNCTION CUTOUT... Displays/adjusts function cutout switch
machine was equipped with a ground alarm and you presence/function
wanted it to sound when driving. There are certain set-
tings allowed to install optional features or select the JIB... Displays/adjusts jib presence
machine model.
GROUND ALARM... Displays/adjusts ground alarm pres-
When selection the machine model to match the size of ence/ function
the machine, the personality settings will all default to the
PLATFORM ALARM... Displays/adjusts platform alarm pres-
factory recommended setting.
ence/ function
NOTE: Refer to Table 6-3, Personality Ranges/Defaults, and BATTERY MONITOR... Displays/adjusts battery monitor, which
Table 6-1, Machine Setup Descriptions in this Ser- indicates “WATER BATTERIES” after a
vice Manual for the recommended factory settings. number of charge/discharge cycles
NOTE: Password 33271 will give you access to level 1,

which will permit you to change all machine person-
ality settings.
6-6 – JLG Lift – 3120772

Machine Configuration Programming

Information
Table 6-2. Machine Configuration Programming Information
Default
Configuration Digit Number Description
Number
NOTE: When configuring the E450, E400, or the E300 machine, the machine configuration must be completed
before any personality settings can be changed. Changing the personality settings first and then changing
the model number of the machine configuration will cause the personality settings to return to default val-
ues.
1 1 Model 300 1
(Model #)
2 Model 400(* See Note Below)
3 Model 45/450(*See Note Below)
NOTE: The elevated drive speed setting must be changed to 10% for E45AJ, M45AJ, M40AJP, E40AJP, M450AJ,
E450AJ, M400AJP, E400AJP, E400A, AND M400A machines going to Europe (CE). Also the elevated drive
speed setting must be changed to 15% for E40AJPn, M40AJPn, E400AJPn, M400AJPn,E400Anarrow, and
M400Anarrow machines going to Europe (CE).
2 1 5 degree-reduces the maximum speed of all boom functions to creep when tilted and 1
(Tilt Switch) above elevation. Reduces drive speed to creep when tilted. Domestic and Japan
2 3 degree-reduces the maximum speed of all boom functions to creep when tilted and
above elevation. Reduces drive speed to creep when tilted. European and Australian
3 3 degree-cuts out drive and reduces boom functions to creep speed when tilted and
above elevation. Reduces drive speed to creep when tilted only. Option
4 3 degree- cuts out drive, telescope out, upper boom lift up and reduces all other boom
functions to creep speed when tilted and above elevation. Option
NOTE: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform
alarm when the machine is tilted and above elevation.
3 0 Battery Charger Cutout-cuts out drive when the battery charger is plugged in. 0
(Drive Cutout)
1 Battery Charger Cutout and Simultaneous Drive and Boom Functions disabled above
elevation. Europe and Australia
2 Battery Charger Cutout and Drive Cutout above elevation. Option
4 0 No Function Cutout 0
(Function Cutout Limit
1 Cuts out all boom functions when switch opens. Option
Switch)
2 Cuts out all functions when switch opens. Option
3120772 – JLG Lift – 6-7

Table 6-2. Machine Configuration Programming Information
Default
Configuration Digit Number Description
Number
5 0 No JIB installed. 0
(JIB)
1 JIB installed which has up and down movements only. Option
2 JIB installed which has up and down movements and side to side movements. Option
6 0 No ground alarm installed. 0

(Ground
Alarm) 1 Travel alarm- Sounds when the drive function is active. Option
2 Descent Alarm- Sounds when either lift down is active. Option
3 Motion alarm- Sounds when any function is active. Option
7 0 Sounds continuously when above elevation and tilted only. 0

(Platform Alarm)
1 Sounds continuously when above elevation and tilted, and in conjunction with fault code
flashes. Option
8 0 No Soft-Touch System Installed

(Soft-Touch) 1 Soft-Touch system Installed
9 0 No Load Cell Installed 0

(Load Cell)
1 Warn Only
2 Warn & Cutout
3 Warn & Boom cutout
4150286-9
6-8 – JLG Lift – 3120772

Machine Personality Settings

NOTE: Personality settings can be adjusted within the
adjustment range in order to achieve optimum
machine performance.
Table 6-3. Personality Ranges/Defaults
FUNCTION PERSONALITY RANGE DEFAULTS
DRIVE ACCELeration 0.5s to 5.0s 1.5
DECELeration 0.1s to 2.0s 0.5
MINimum speed 0 to 25% 3
MAXimum speed 0 to 100% 95
ELEVATED MAXimum speed 0 to 25% 20
CREEP MAXimum speed 0 to 45% 30
POSITRAC time 0 to 60s 10
POSITRAC current 50-250 A 170A
LOWER LIFT ACCELeration 0.5 to 5.0s 1.0
DECELeration 0.0 to 3.0s 0.5
MINimum UP speed 0 to 30% 11
MAXimum UP speed 0 to 100% 100
MINimum DOWN speed 0 to 20% 9
MAXimum DOWN speed 0 to 100% 70
UPPER LIFT ACCELeration 0.5 to 5.0 1.0
DECELeration 0.1 to 5.0 0.3
MlNimum UP speed 0 to 20 4
MAXimum UP speed 0 to 100 90
CREEP Maximum UP speed 0 to 50 27
MINimum DOWN speed 0 to 10 1
MAXimum DOWN speed 0 to 100 80
CREEP maximum DOWN speed 0 to 30 18
3120772 – JLG Lift – 6-9

SWING ACCELeration 0.5 to 5.0s 2.0
DECELeration 0.0 to 3.0s 1.5
MINimum LEFT speed 0 to 10% 6
MAXimum LEFT speed 0 to 60% 33
CREEP maximum LEFT speed 0 to 35% 12
MINimum RIGHT speed 0 to 10% 6
MAXimum RIGHT speed 0 to 60% 33
CREEP maximum RIGHT speed 0 to 35% 12
TELEscope ACCELeration 0.5 to 5.0 1.0
MINimum IN speed 0 to 20 8
MAXimum IN speed 0 to 100 60
MINimum OUT speed 0 to 20 7
MAXimum OUT speed 0 to 100 40
BASKET LEVEL ACCELeration 0.5 to 5.0 1.0
MINimum UP speed 0 to 20 7
MlNimum DOWN speed 0 to 20 9
BASKET ROTATE ACCELeration 0.5 to 5.0 2.0
MlNimum LEFT speed 0 to 15 6
MAXimum LEFT speed 0 to 100 20
MINimum RIGHT speed 0 to 15 5
MAXimum RIGHT speed 0 to 100 20
6-10 – JLG Lift – 3120772

JIB ACCELeration 0.5 to 5.0 1.5
MINimum UP speed 0 to 50 9
MINimum DOWN speed 0 to 25 6
JIB SWING MINimum RIGHT speed 0 to 50 5
MAXimum RIGHT speed 0 to 100 20
MINimum LEFT speed 0 to 50 5
MAXimum LEFT speed 0 to 100 20
STEER MINimum speed 0 to 100 75
MAXimum speed 0 to 100 100
GROUND MODE Lower LIFT UP speed 0 to 100 75
Lower LIFT DOWN speed 0 to 100 53
UPPER LIFT speed 0 to 100 75
SWING speed 0 to 100 25
TELEscope speed 0 to 100 45
BASKET ROTATE speed 0 to 100 20
BASKET LEVEL speed 0 to 100 30
JIB SWING speed 0 to 100 45
JIB LIFT speed 0 to 100 42

4150285-
3120772 – JLG Lift – 6-11

Level Vehicle Description Help Descriptions and Fault Flash Codes
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE. Table 6-4. JLG Control System Flash Codes
Code Description
2-1 Faulty Footswitch/EMS

LEVEL VEHICLE 2-2 Drive/Steer inputs/Footswitch Interlocks
YES:ENTER, NO:ESC
2-3 Boom function inputs/Lift-Swing Joystick
2-5 Function Cutout/Drive Cutout
3-1 Contactors miswired/Motors miswired
3-2 Line contactor welded
3-3 Contactor short circuit or valve short circuit
3-5 Brake pressure input
4-2 Controller Over temperature
4-4 Battery voltage out of range
5-5 Speed Sensor input
6-6 CANbus inputs
7-7 Traction /Pump motor wiring or motor faulty
9-9 Power Module Failure
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2 ENTER confirms that

vehicle is currently level, and zeroes the tilt sensor mea-
surements
6-12 – JLG Lift – 3120772

Table 6-5. Help Descriptions and Fault Flash Codes
Flash Code Description

No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is not behaving as expected.
EVERYTHING OK
The “normal” help message in platform mode
GROUND MODE OK
The “normal” help message in ground mode
BRAKES RELEASED
Indicates manual brake release in ground mode
DRIVING AT CREEP - TILTED
Drive speed is limited to creep because the vehicle is tilted.
FWS
A drive or boom function has been selected but footswitch is open.
PUMP MOTOR AT CURRENT LIMIT
Pump current has reached controller current limit or safe operating area limit.
RUNNING AT CREEP - CREEP SWITCH OPEN
All function speeds are limited to creep because the creep switch is open.
RUNNING AT CUTBACK - ABOVE ELEVATION
All function speeds are limited to cutback speed because the vehicle is above elevation.
RUNNING AT CREEP - TILTED AND ABOVE ELEVATION
All function speeds are limited to creep because the vehicle it tilted and above elevation.
TESTS ACTIVE - RECYCLE EMS TO END
The system tests have been activated; normal vehicle operation is not allowed.
TILT MODULE FAILURE: BAD TILT SENSOR
There is a problem with the tilt sensor interface circuitry; the controller defaults to massively tilted and does
not try to prevent vehicle roll on the grade.
TRACTION MOTOR AT CURRENT LIMIT
Traction current has reached controller current limit or safe operating area limit.
WATER BATTERIES
The batteries have been charged a number of times (set by machine digit) and need a top-up; when this is
done the count will reset
2/1 Flash code 2/1 indicates problems with the footswitch.
FWS FAULTY
The two footswitch signals do not agree. EMS recycle required.
START UP
Neither EMS input is active - the system is just switching on or is discharging the capacitor bank. A welded
line contactor might also cause this
3120772 – JLG Lift – 6-13

2/2 Flash code 2/2 indicates problems with drive & steer selection.
DRIVE JOYSTICK FAULTY
The drive joystick center tap is out of valid range, or the wiper is wire-off.
DRIVE LOCKED - JOYSTICK MOVED BEFORE EMS/FWS
Drive was selected before and during footswitch closure.
FWS INTERLOCK TRIPPED
Footswitch was closed for seven seconds with no function selected.
STEER LOCKED - SELECTED BEFORE EMS/FWS
Steer was selected before and during footswitch closure.
STEER SWITCHES FAULTY
Both steer switches are active together.
WAITING FOR FWS TO BE OPEN
Footswitch was closed when platform mode was selected.
JOYSTICK FAULTS - CHECK PLATFORM BOX WIRING
More than one of the drive, lift and swing joystick center tap or wiper voltages is out of range.
This is probably due to a short-circuit across a joystick port.
2/3 Flash code 2/3 indicates problems with boom function selection.
LIFT/SWING JOYSTICK FAULTY
The lift or swing Joystick center tap is out of valid range, or the wiper is wire-off.
LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE EMS/FWS
Upper Lift or swing was selected before and during footswitch closure.
PUMP POT FAULTY
The pump pot is open-circuit; All platform boom functions except upper lift & swing will run at creep.
PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM
A boom function (lower lift, telescope, basket level, basket rotate, jib) has both directions selected together.
PUMP SWITCHES LOCKED - SELECTED BEFORE EMS/FWS
A boom function (lower lift, telescope, basket level, basket rotate, jib) was selected before and during foot-
switch closure.
PUMP SWITCHED LOCKED - SELECTED BEFORE EMS
A ground boom function (lower lift, telescope, basket level, basket rotate, jib,) was selected before key
switch
SWING/LIFT JOYSTICK FAULTY
The swing joystick center tap is out of valid range, or the wiper is wire-off.
6-14 – JLG Lift – 3120772

2/5 Flash code 2/5 indicates that a function is prevented due to a cutout.
BOOM PREVENTED - DRIVE SELECTED
A boom function is selected while a drive function is selected and drive cutout is configured to prevent
simultaneous drive & boom operation.
BOOM PREVENTED - FUNCTION CUTOUT ACTIVE
A boom function is selected while function cutout is active and configured to cutout boom functions.
DRIVE & BOOM PREVENTED - FUNCTION CUTOUT ACTIVE
Drive or a boom function is selected while function cutout is active and configured to cutout all functions.
DRIVE PREVENTED - ABOVE ELEVATION
Drive is selected while above elevation and drive cutout is configured to prevent drive.
DRIVE PREVENTED - BOOM MOVEMENT SELECTED
Drive is selected while a boom function is selected and drive cutout is configured to prevent simultaneous
drive & boom operation.
DRIVE PREVENTED - CHARGER CONNECTED
Drive is selected while the charger is on (indicated by drive cutout being active) and drive cutout is config-
ured to prevent drive.
DRIVE PREVENTED - TILTED ABOVE ELEVATION
Drive is selected while drive cutout is active and drive cutout is configured to prevent drive.
3/1 Flash code 3/1 indicates that a contactor did not close when energized.
LINE & DIRECTION CONTACTORS MISWIRED
When the line contactor was closed traction point A went high (and the capacitor bank charge did not
increase to battery supply) - this occurs if the line contactor coil wiring is swapped with that for a direction
contactor coil.
OPEN-CIRCUIT FORWARD DIRECTION CONTACTOR OR TRACTION MOTOR
Traction point A did not go high when forward contactor was energized (this could be due to traction motor
open-circuit or a power wiring error).
OPEN-CIRCUIT LINE CONTACTOR
The capacitor bank charge did not increase to battery supply when line contactor was energized (this could
be due to a power wiring error).
OPEN-CIRCUIT REVERSE DIRECTION CONTACTOR OR TRACTION MOTOR
Traction point A did not go high when reverse contactor was energized (this could be due to traction motor
open-circuit or a power wiring error).
3/2 Flash code 3/2 indicates that a contactor did not open when energized.
WELDED LINE CONTACTOR
The capacitor bank charge did not decrease from battery supply when line contactor was deenergized (this
could be due to a power wiring error).
WARNING: If the line contactor is welded, the controller will not switch off when EMS or key switch is turned
off.
3/3 Flash code 3/3 indicates that a contactor coil is short-circuited.
OVERLOADED VALVE SUPPLY-CHECK WIRING.
There is a high current draw from the valve supply when no valve is energized; this is probably due to a wir-
ing error at the ground module.
SHORT-CIRCUIT FORWARD CONTACTOR COIL
The forward contactor was not energized when required, due to coil over current protection.
SHORT-CIRCUIT LINE CONTACTOR COIL
The line contactor was not energized when required, due to coil over current protection.
SHORT-CIRCUIT REVERSE CONTACTOR COIL
The reverse contactor was not energized when required, due to coil over current protection.
3120772 – JLG Lift – 6-15

3/5 Flash code 3/5 indicates that there is a brake pressure problem.
BRAKES DID NOT LOCK
Brake pressure did not clear when the brake valve was deenergized.
BRAKES DID NOT RELEASE
No brake pressure was detected when running the pump motor and energizing the brake valve
4/2 Flash code 4/2 indicates that the controller is over temperature.
CONTROLLER TOO HOT - PLEASE WAIT
The controller heat sink temperature reached 75 degrees. The controller is shut down until it cools to below
70 degrees.
4/4 Flash code 4/4 indicates problems with the battery supply.
BATTERY LOW
Battery voltage is below 40V. This is a warning - the controller does not shut down.
BATTERY TOO HIGH - SYSTEM SHUT DOWN
Battery voltage is above 62V.
EMS recycle required.
BATTERY TOO LOW - SYSTEM SHUT DOWN
Battery voltage is below 33V.
EMS recycle required.
5/5 Flash code 5/5 indicates problems with vehicle speed or the encoder.
NO VEHICLE MOVEMENT DETECTED AT MAXIMUM POWER
No speed was measured with traction motor full on. This could be due to a traction motor fault, a power wir-
ing error, a speed encoder fault, the brakes not releasing (although brake Pressure is OK) or the vehicle
being overloaded so that the motor cannot turn the wheels.
DRIVE PREVENTED - BOTH SPEED ENCODERS FAULTY
Both speed encoder input voltages are out of range.
LEFT SPEED ENCODER FAULTY
The left speed encoder input voltages are out of range. The vehicle will continue to drive at cutback using
the right speed encoder.
TILT MODULE FAILURE; NOT COMMUNICATING
There is a problem with the positrac/tilt module; The controller defaults to massively tilted and does not try
to prevent vehicle roll on grade.
RIGHT SPEED ENCODER FAULTY
The right speed encoder input voltages are out of range. The vehicle will continue to drive at cutback using
the left speed encoder.
SPEED ENCODERS READING INVALID SPEED
One or both speed encoders is indicating an impossible number of pulses. This is probably due to a faulty
speed encoder.
VEHICLE RUNAWAY - CHECK SPEED ENCODERS
Speed in the wrong direction was measured with traction motor full on. This is probably due to the speed
encoder being fitted incorrectly; it could also be due to a speed encoder fault or faults as for “NO VEHICLE
MOVEMENT DETECTED” with the vehicle on a grade.
6-16 – JLG Lift – 3120772

6/6 Flash code 6/6 indicates problems with the CANbus.

48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING
The power module is not receiving acknowledgments from the platform or ground modules to transmitted
data, and the protection circuit which supplies the platform and ground modules has tripped. This is proba-
bly due to wiring problems at the platform or ground module.
CANbus FAILURE: GROUND MODULE
The power module is receiving from the platform module but not the ground module. This should not be
possible!
CANbus FAILURE: PLATFORM MODULE
The power module is receiving from the ground module but not the platform module. This is probably due
to wiring problems between the platform and ground modules.
CANbus FAILURE: POWER MODULE The power module is not receiving acknowledgments from the plat-
form or ground modules to transmitted data. This is probably due to wiring problems between the ground
and power modules.
7/7 Flash code 7/7 indicates problems with a motor.
CAPACITOR BANK FAULT - CHECK POWER CIRCUITS
The capacitor bank is not charging. This is probably due to a power wiring error causing illegal current
drain; it could also be due to a very low battery supply.
OPEN-CIRCUIT PUMP MOTOR
Pump point A is collapsing when the pump MOSFETs are pulsed. This is probably due to an open circuit
pump motor or a power wiring error.
OPEN-CIRCUIT DIRECTIONAL CONTACTOR OR TRACTION MOTOR
Traction point A is collapsing when the traction MOSFETs are pulsed. This is probably due to an open cir-
cuit traction motor or a power wiring error. NOTE: This fault is unlikely to be seen due to interaction with
speed control...
PUMP POINT A LOW - CHECK POWER CIRCUITS
Pump point A is near 0V when the pump MOSFETs are off. This is probably due to a power
STALLED TRACTION MOTOR
The power module traction MOSFET protection circuit is active. This is due to massive current drain and
could be a stalled traction motor or a power wiring error.
STALLED PUMP MOTOR
The power module pump MOSFET protection circuit is active. This is due to massive current drain and
could be a stalled pump motor or a power wiring error.
TRACTION MOTOR OVERLOADED
The traction motor has been operating in current limit at a low percentage on for a period of time greater
than 10 seconds.
PUMP MOTOR OVERLOADED
The pump motor has been operating in current limit at a low percentage on for a period of time greater than
10 seconds.
TRACTION CURRENT AT ZERO - CHECK SHUNT WIRING
Traction current measurement is at zero. This is probably due to an open-circuit between the current mea-
surement shunt and the power module.
TRACTION POINT A HIGH - CHECK POWER CIRCUITS
Traction point A is near battery supply when neither direction contactor is energized and the traction MOS-
FETs are off. This could be due to a welded direction contactor or a power wiring error.
TRACTION POINT A LOW - CHECK POWER CIRCUITS
Traction point A is near 0V when neither direction contactor is energized and the traction MOSFETs are off.
This could be due to a power wiring error.
3120772 – JLG Lift – 6-17

9/9 Flash code 9/9 indicates problems with the controller.

POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1
A contactor remained energized when turned off.
POWER MODULE FAILURE: HWFS CODE 2
The hardware fail-safe tests did not complete because traction point A is not safe, or the hardware fail-safe
is permanently tripped.
The hardware fail-safe tests did not complete because a contactor was energized when all should be turned
off
The hardware fail-safe tests did not complete because the hardware fail-safe tripped immediately when the
traction MOSFETs were turned on.
The hardware fail-safe tests failed because the hardware fail-safe did not trip within the allowed test time.
The hardware fail-safe tests failed because the hardware fail-safe tripped too slowly.
The hardware fail-safe tests failed because the hardware fail-safe tripped too quickly.
The hardware fail-safe tests failed because the hardware fail-safe remained tripped when the traction MOS-
FETs were turned off.
The hardware fail-safe tests failed because the line contactor could still be energized when the hardware
fail-safe was tripped
The hardware fail-safe tests failed because the contactor drive fail-safe did not trip within the allowed test
time.
The hardware fail-safe tests failed because the contactor drive fail-safe tripped too slowly.
The hardware fail-safe tests failed because the contactor drive fail-safe tripped too quickly.
POWER MODULE FAILURE: HWFS TEST STALLED
The hardware fail-safe tests did not complete, but no reason can be determined.
POWER MODULE FAILURE: BAD TEMPERATURE SENSOR
The temperature sensor measurement is invalid, this is probably due to a disconnected wire within the
power module. The possibility of other disconnected wires (which could cause dangerous system function)
means that the controller is shut down.
POWER MODULE FAILURE: S/C LINE CONTACTOR DRIVER The line contactor energized when the foot-
switch was closed, before it was turned on, this is probably due to a failed driver within the power module,
although it could be due to bad power module wirings
6-18 – JLG Lift – 3120772

Figure 6-3. Analyzer Flow Chart - Sheet 1 of 2
3120772 – JLG Lift – 6-19

Figure 6-4. Analyzer Flow Chart - Sheet 2 of 2
6-20 – JLG Lift – 3120772

Analyzer Diagnostics Menu Structure the next outer level. The LEFT/RIGHT arrow keys move
between items in the same level. The UP/DOWN arrow
In the following structure descriptions, an intended item is
keys alter a value if allowed
selected by pressing ENTER; pressing ESC steps back to
Table 6-6. Diagnostics - Menu Descriptions

DRIVE
DRIVE... Displays drive joystick direction & demand
SPEED... Displays vehicle direction & speed
POSITRAC... Displays positrac status
STEER... Displays steer switch direction & demand
NOTE: steer demand is inversely proportional to vehicle speed
BRAKES... Displays brake control system status
CREEP... Displays pump pot creep switch status
BOOM
LL.... Displays lower lift switch direction & demand
NOTE: demand is controlled by the pump pot
UL. Displays upper lift joystick direction & demand
SWING... Displays swing joystick direction & demand
LEVEL. Displays basket level switch direction & demand
TELE... Displays telescope switch direction & demand
ROTATE. Displays basket rotate switch direction & demand
JIB (U/D). Displays jib lift switch direction & demand
NOTE: demand is controlled by the pump pot Not displayed if
JIB = NO
JIB (L/R) Displays jib swing switch direction & demand
NOTE: demand is controlled by the pump pot Not displayed if
JIB = NO
PUMP POT... Displays pump pot demand
CREEP... Displays pump pot creep switch status
SYSTEM
TRACTION... Displays measured traction motor current
PUMP... Displays measured pump motor current
VALVE... Displays measured valve (12V supply) current
NOTE: this includes current for the ground alarm & hourmeter,
but not for any lamps
BATTERY... Displays measured battery voltage
TEMPERATURE... Displays measured heat sink temperature
FSW1... Displays footswitch status
FSW2... Displays footswitch status
NOTE: FSW2 is wired to the platform module
DRIVE CUTOUT... Displays drive cutout switch status
ELEV. CUTOUT... Displays elevation cutout switch status
FUNC. CUTOUT... Displays function cutout switch status
BRAKES... Displays brake pressure switch status
MAN.RELEASE... Displays manual brake release switch status
3120772 – JLG Lift – 6-21

Table 6-6. Diagnostics - Menu Descriptions

TILT... Displays measured vehicle tilt
The first value indicates tilt in die forwards reverse direction
(pitch)
The second value indicates tilt in the left/ right direction (roll)
DATALOG
MAX.TEMP... Displays maximum measured heat sink temp.
MIN.TEMP... Displays minimum measured heat sink temp.
MAX. BATTERY. Displays maximum measured battery voltage
ON... Displays total controller on (EMS) time
DRIVE... Displays total controller drive operation time
PUMP... Displays total controller pump running time
NOTE: includes all boom functions, steer and brake release
LIFT. Displays total controller lift operation time
SWING... Displays total controller swing operation time
TELE... Displays total controller tell operation time
RENTAL... Displays total controller operation time
NOTE: can be reset
ERASE RENTAL Not available at password level 2
YES:ENTER, NO:ESC ENTER Enter resets rental datalog time to zero
VERSIONS
POWER Displays power software version
PLATFORM Displays platform software version
GROUND Displays ground software version
POSITILT Displays positilt software version
ANALYZER Displays analyzer software version
System Self Test closure of the input. If the operator knows the switch
is faulty and wants to continue the tests he must
The system self test is utilized to locate typical problems. simply press the enter key on the analyzer to con-
See Table 6-7, System Test Descriptions for information tinue.
concerning the tests performed and available messages
in this mode. 3. After the controller has conducted the tests from the
chosen operator station, it will display “TESTS COM-
1. When the key switch is in the platform position and PLETE”. This indicates that the controller has
the self test enabled, the self test function will test all checked all inputs and outputs for that station.
valves, contactors, platform inputs, indicator lamps,
and system alarms for various fault conditions.
When the key switch is in the ground position, the IN ORDER FOR THE MACHINE TO FUNCTION AFTER THE SELF
self test function will test all valves, the line contac- TEST IS COMPLETE, POWER MUST BE RECYCLED USING THE
tor, ground control inputs, and the ground alarm out- EMS OR THE KEY SWITCH.
put for various fault conditions.
2. In order to test the inputs on the machine, the con-
troller will ask the service technician to perform vari-
ous tasks at the appropriate operator control station.
An example of this is “Close LLU Switch”. The con-
troller expects the operator to close the lower lift up
switch. When the controller sees that the lower lift up
switch has been closed, it will move on to the next
input, lower lift down LLD. If the switch is faulty or the
wiring is faulty, the controller will not move on to the
next input. The controller will continue to wait for the
6-22 – JLG Lift – 3120772

Table 6-7. System Test Descriptions
ACTIVATE TESTS Not available once tests are activated

YES:ENTER, NO:ESC ENTER activates system tests
NOTE: cannot be done while controller is in use (footswitch closed) and for a short
time afterwards
RUN SYSTEM TEST ENTER starts system test
Not available until tests are activated Displays messages while system test
runs Some messages are prompts, requiring user intervention.
ENTER can be pressed if a fault is found, to confirm that the fault has been
noted and to continue the system test.
NOTE: a flashing message is critical, and prevents the system test running
3120772 – JLG Lift – 6-23

Table 6-8. System Test Messages
RUNNING Initial display when system test is run; certain “critical” checks are made. Problems which can be reported include:
ONLY 1 ANALYZER!
Do not connect two Analyzers while running the system test.
BAD POWER WIRING
The capacitor bank is not charged or pump point A is low or traction point A is high or low.
Check all power wiring.
LINE CONT WELDED
The capacitor bank is at battery voltage.
Check line contactor.
Check all power wiring.
BATTERY TOO LOW
The system test cannot run with battery voltage below minimum.
BATTERY TOO HIGH
The system test cannot run with battery voltage above maximum.
CHECK CAN WIRING
The system test cannot run in platform mode unless data is being received from the
platform, ground and positrac/tilt modules. The system test cannot run in ground mode
unless data is being received from the ground and positrac/tilt modules.
CHECK LEFT SPD.
There is an open- or short- circuit in the left speed encoder wiring. Check left speed
encoder.
CHECK RIGHT SPD.
There is an open- or short- circuit in the right speed encoder wiring. Check right speed
encoder.
CHECK SHUNT
The traction current measurement is open-circuit.
Check wiring between power module contactor panel.
BAD PUMP WIRING
Pump point A is not high, probably caused by an open-circuit pump motor or wiring.
Check all power wiring. Check pump motor.
BAD POWER WIRING
Traction point A is high, probably caused by incorrect faction motor wiring. Check all
power wiring. Check traction motor.
BAD POWER MODULE
An internal problem was detected in the power module.
HIGH TILT ANGLE
The vehicle is very tilted, or the tilt sensor has been damaged. Check tilt sensor.
HOT POWER MODULE
The heat sink temperature exceeds 75°C; this is only a warning.
BAD I/O PORTS
The controller detected a problem with its internal circuits at switch on. If other problems
are also detected, the controller may need replacing.
SUSPECT EEPROM
The controller detected a problem with its EEPROM stored personality settings at
switch on. Check and, if necessary correct, all personality settings.
WAIT:CAPBANK HI
This message can be displayed if the system test is run shortly after the vehicle was used;
after a short wait, it should clear.
OPEN FWS
In platform mode, the footswitch must be open at the start of the test.
CLOSE FWS
In platform mode, the footswitch must be closed when this message is displayed; the foot
switch MUST BE KEPT CLOSED during the valve & contactor tests.
BAD FWS
The two footswitch signals are not changing together, probably because one is
open-circuit. One footswitch signal (“FSW1”) is routed to the power module, the other
(“FSW2”) is routed to the platform module. Check footswitch and wiring.
6-24 – JLG Lift – 3120772


TESTING VALVES Indicates that the valve test is beginning.
Each valve is alternately energized and de-energized; checks are made for open-and short- circuit
valve coils.
The valves are tested in the order: PROP (main proportional), LL U, LL D, UL U, UL D, SWING L,
SWING R, SWING REST, LEVEL U, LEVEL D, ROTATE L, ROTATE R, JIB U, JIB D,
TELE I, TELE O, BYPASS, STEER L, STEER R, STEER PROP, BRAKE
NOTE: in platform mode, the footswitch must be closed.
NOTE: jib valves are not tested if JIB = NO
NOTE: left/right jib are not tested unless jib = side swing.
Problems which can be reported include:
CANT TEST VALVES
There is a wiring problem which prevents the valve test from functioning correctly.
Check valve wiring.
Check ground alarm wiring.
valve name S/C
The named valve is drawing too much current so is presumed to be short-circuit.
Check valve wiring.
valve name O/C
The named valve is drawing too little current so is presumed to be open-circuit.
Check valve wiring.
VALVE TEST DONE Indicates that the valve test is complete (with or without faults).
TESTING CONTS Indicates that the contactor test is beginning.
In platform mode, the forward & reverse direction contactors are energized and de-energized; checks are made that they
close & open correctly and for short-circuit coils.
In platform and ground mode, the line contactor is energized and de-energized; checks are made that it closed & opened
correctly and for a short-circuit coil.
In platform mode, the positrac contactors are energized and de-energized; checks are made for short-circuit and open-
circuit coils.
CANT TEST CONTS
There is a wiring problem which prevents the contactor test from functioning correctly.
Check power wiring.
Check contactor wiring.
BAD CONT WIRING
There is a wiring problem which caused the capacitor bank to be charged when a direction contactor was
energized; probably the wiring to the contactor coils is incorrect.
Check power wiring.
contname WELDED
The named contactor appears to have not opened.
Check named contactor.
Check power wiring.
contname COIL S/C
The named contactor coil overloaded its driver circuit so is presumed to be short-circuit.
contname DIDN’T CLOSE
The named contactor appears to have not closed.
Check power wiring.
CONT TEST DONE Indicates that the contactor test is complete (with or without faults).
3120772 – JLG Lift – 6-25

CHECKING INPUTS Indicates that the inputs test is beginning.

Every input is checked to ensure that it is in its “normal” position; function switches should be open,
cutout switches should be closed, joysticks should be in neutral.
In platform mode, inputs are tested in the order: UL U, UL D, UL JOY., SWING L, SWING R,
SWING JOY., LEVEL U, LEVEL D, PUMP POT., ROTATE L, ROTATE R, LL U, LL D, JIB U, JIB D,
TELE I, TELE O, DRIVE FWD, DRIVE REV, DRIVE JOY., STEER L, STEER R,
POSITRAC, DRIVE C/O, ELEV. C/O, FUNC. C/O, BRAKE PRES
In ground mode, inputs are tested in the order: ROTATE L, ROTATE R, LEVEL U. LEVEL D, JIB U.
JIB D, TELE I, TELE O, UL U, UL D, LL U, LL D, SWING L, SWING R, ELEV. C/O,
FUNC. C/O, BRAKE PRES, MAN. BRAKE
NOTE: switches which are not in use (due to the settings of machine digits) are not checked. NOTE: the pump pot is
checked only for a wire-off condition; it can be at any demand from creep to
maximum.
CHECK switch name
The named switch is not in its “normal” position.
Check switch & wiring.
CHECK switch name JOY.
The named joystick appears to be faulty.
Check joystick.
INPUTS DONE Indicates that the inputs test is complete (with or without faults).
TESTING LAMPS Indicates that the lamps test is beginning.
Each lamp is energized in turn; a prompt asks for confirmation that the lamp is lit - ENTER must be
pressed to continue the test.
Lamps are tested in the order: ENABLE, FAULT, TILT, CREEP, POSlTRAC, WATER.
NOTE: lamps which are not in use (due to the settings of machine digits) are not checked.
NOTE: lamps are only tested in platform mode.
lamp name S/C
A short-circuit condition appeared while the named lamp was being tested, presumably
because it is short-circuit.
LAMP TEST DONE Indicates that the lamps test is complete.
TESTING ALARMS Indicates that the alarms test is beginning.
Each alarm is energized in turn; a prompt asks for confirmation that the alarm is sounding - ENTER
must be pressed to continue the test.
Alarms are tested in the order: P.ALARM, G.ALARM.
NOTE: the platform alarm is only tested in platform mode.
NOTE: the ground alarm is not tested if GROUND ALARM = NO.
alarm name S/C
A short-circuit condition appeared while the named alarm was being tested, presumably
because it is short-circuit.
ALARM TEST DONE Indicates that the alarms test is complete.
6-26 – JLG Lift – 3120772


TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends.
If ENTER is pressed, each operator input is prompted for in turn.
In platform mode, operator inputs are tested in the order: UL U, UL D, SWING L, SWING R, LEVEL U, LEVEL D,
PUMP POT, CREEP, ROTATE L, ROTATE R, LL U, LL D, JIB U, JIB D, TELE I, TELE O, DRIVE FWD,
DRIVE REV, STEER L, STEER R, POSITRAC
In ground mode, operator inputs are tested in the order: ROTATE L, ROTATE R. LEVEL U. LEVEL D, JIB U. JIB D,
TELE I, TELE O. UL U. IJL D, LL U. LL D, SWING L, SWING R
NOTE: the jib switches are not tested if JIB = NO.
Prompts displayed during the operator input test include:
CLOSE switch name
The named switch should be closed.
OPEN switch name
The named switch should be opened.
joystick name direction TO MAX
The named joystick should be pushed to its full extent in the named direction.
joystickname direction TO MIN
The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX
The pump pot should be turned to maximum.
PUMP POT TO MIN
The pump pot should be turned to minimum.
MULTIPLE CLOSURE
More than one operator input is closed; if only one has been operated, there could be a short between two inputs.
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and should now be rectified.
Press ESC to return to the RUN SYSTEM TEST Analyzer menu.
3120772 – JLG Lift – 6-27

NOTES:
6-28 – JLG Lift – 3120772

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL device under test correctly. Also check that the lead on the
"COM" port goes to the Ground or negative side of the sig-
This section contains basic electrical information and nal and the lead on the other port goes to the positive side
schematics to be used for locating and correcting most of of the signal.
the operating problems which may develop. If a problem
should develop which is not presented in this section or Scale
which is not corrected by listed corrective actions, techni-
cally qualified guidance should be obtained before pro- M = Mega = 1,000,000 * (Displayed Number)
ceeding with any maintenance. k = kilo = 1,000 * (Displayed Number)
7.2 MULTIMETER BASICS m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM) µ = micro = (Displayed Number) / 1,000,000
can be used for troubleshooting your equipment. This Example: 1.2 kΩ = 1200 Ω
section shows diagrams of a common, digital VOM con- Example: 50 mA = 0.05 A
figured for several different circuit measurements. Instruc-
tions for your VOM may vary. Please consult the meter Voltage Measurement
operator’s manual for more information.
Grounding
"Grounding the meter" means to take the black lead
(which is connected to the COM (common) or negative
port) and touch it to a good path to the negative side of
the Voltage source.
Backprobing
To "backprobe" means to take the measurement by
accessing a connector’s contact on the same side as the
wires, the back of the connector. Readings can be done
while maintaining circuit continuity this way. If the connec-
tor is the sealed type, great care must be taken to avoid
damaging the seal around the wire. It is best to use
probes or probe tips specifically designed for this tech-
nique, especially on sealed connectors. Whenever possi-
ble insert probes into the side of the connector such that
the test also checks both terminals of the connection. It is
possible to inspect a connection within a closed connec-
tor by backprobing both sides of a connector terminal and
measuring resistance. Do this after giving each wire a
gentle pull to ensure the wires are still attached to the con- Figure 7-1. Voltage Measurement (DC)
tact and contacts are seated in the connector.
• If meter is not auto ranging, set it to the correct
Min/Max range (See multimeter’s operation manual)
Use of the "Min/Max" recording feature of some meters • Use firm contact with meter leads
can help when taking measurements of intermittent condi-
tions while alone. For example, you can read the Voltage
applied to a solenoid when it is only operational while a
switch, far from the solenoid and meter, is held down.
Polarity
Getting a negative Voltage or current reading when
expecting a positive reading frequently means the leads
are reversed. Check what reading is expected, the loca-
tion of the signal and that the leads are connected to the
3120772 – JLG Lift – 7-1

Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to

enable audible continuity testing
• Circuit power must be turned OFF before testing
Figure 7-2. Resistance Measurement continuity
• First test meter and leads by touching leads • Disconnect component from circuit before testing
together. Resistance should read a short circuit
• Use firm contact with meter leads
(very low resistance)
• First test meter and leads by touching leads
• Circuit power must be turned OFF before testing
together. Meter should produce an audible alarm,
resistance
indicating continuity
• Disconnect component from circuit before testing
range (See multimeter’s operation manual)
7-2 – JLG Lift – 3120772

Current Measurement the inside of the connector prior to assembly. This is

most easily achieved by using a syringe.
NOTE: Over a period of time, oxidation increases electrical

resistance at the connection, eventually causing cir-
cuit failure.
2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female con-
nectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the con-
nector should also be sealed.
NOTE: This condition is especially common when machines

are pressure washed since the washing solution is
much more conductive than water.
3. Anderson connectors for the battery boxes and bat-

tery chargers should have silicone grease applied to
the contacts only.
NOTE: Curing-type sealants might also be used to prevent

shorting and would be less messy, but would make
future pin removal more difficult.
Figure 7-4. Current Measurement (DC)
• Set up the meter for the expected current range

• Be sure to connect the meter leads to the correct
jacks for the current range you have selected
range (See multi meter’s operation manual)
7.3 APPLYING SILICONE DIELECTRIC

COMPOUND TO ELECTRICAL
CONNECTIONS
Silicone Dielectric Compound must be used on all electri-
cal connections for the following reasons:
• To prevent oxidation at the mechanical joint between

male and female pins.
• To prevent electrical malfunction caused by low level
conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors. This procedure
applies to all plug connections not enclosed in a box. Sili-
cone grease should not be applied to connectors with
external seals.
1. To prevent oxidation, silicone grease must be
packed completely around male and female pins on
3120772 – JLG Lift – 7-3

7.4 AMP CONNECTOR Assembly

Check to be sure the wedge lock is in the open, or as-
Applying Silicone Dielectric Compound to shipped, position (See Figure 7-5.). Proceed as follows:
AMP Connectors
Silicone Dielectric Compound must be used on the AMP
connections for the following reasons:
• To prevent oxidation at the mechanical joint between

male and female pins.
• To prevent electrical malfunction caused by low level
conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, sili-
cone dielectric grease must be packed completely
around male and female pins on the inside of the
connector after the mating of the housing to the
header. This is easily achieved by using a syringe to
fill the header with silicone dielectric compound, to a
point just above the top of the male pins inside the
header. When assembling the housing to the
header, it is possible that the housing will become
Figure 7-5. Connector Assembly Figure 1
air locked, thus preventing the housing latch from
engaging.
2. Pierce one of the unused wire seals to allow the 1. To insert a contact, push it straight into the appropri-
trapped air inside the housing to escape. ate circuit cavity as far as it will go (See Figure 7-7.).
3. Install a hole plug into this and/or any unused wire 2. Pull back on the contact wire with a force of 1 or 2
seal that has silicone dielectric compound escaping lbs. to be sure the retention fingers are holding the
from it. contact (See Figure 7-7.).
Figure 7-6. AMP Connector
7-4 – JLG Lift – 3120772

3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-9.).
Release the locking latches by squeezing them
inward (See Figure 7-8.).
3120772 – JLG Lift – 7-5

Figure 7-10. Connector Disassembly
Disassembly Service - Voltage Reading

1. Insert a 4.8 mm (3/16") wide screwdriver blade DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READ-
between the mating seal and one of the red wedge INGS.
lock tabs.
It has been common practice in electrical troubleshooting
2. Pry open the wedge lock to the open position.
to probe wires by piercing the insulation with a sharp
3. While rotating the wire back and forth over a half point. This practice should be discouraged when dealing
turn (1/4 turn in each direction), gently pull the wire with the AMPSEAL plug assembly, or any other sealed
until the contact is removed. connector system. The resulting pinholes in the insulation
will allow moisture to invade the system by traveling along
NOTE: The wedge lock should never be removed from the
the wire strands. This nullifies the effectiveness of the con-
housing for insertion or removal of the contacts.
nector seals and could result in system failure.
Wedge Lock
The wedge lock has slotted openings in the forward, or
mating end. These slots accommodate circuit testing in
the field, by using a flat probe such as a pocket knife. DO
NOT use a sharp point such as an ice pick.
7-6 – JLG Lift – 3120772

Figure 7-11. Connector Installation
3120772 – JLG Lift – 7-7

7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal
1. Remove wedgelock using needlenose pliers or a

1. Grasp crimped contact about 25mm behind the con- hook shaped wire to pull wedge straight out.
tact barrel.
2. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you.
while at the same time releasing the locking finger
3. Push contact straight into connector grommet until a by moving it away from the contact with a screw-
click is felt. A slight tug will confirm that it is properly driver.
locked in place.
3. Hold the rear seal in place, as removing the contact
4. Once all contacts are in place, insert wedgelock with may displace the seal.
arrow pointing toward exterior locking mechanism.
The wedgelock will snap into place. Rectangular
wedges are not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure

for plug.
7-8 – JLG Lift – 3120772

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact

1. With rear insert toward you, snap appropriate size
crimp barrel.
extractor tool over the wire of contact to be
2. Hold connector with rear grommet facing you. removed.
3. Push contact straight into connector grommet until a 2. Slide tool along into the insert cavity until it engages
positive stop is felt. A slight tug will confirm that it is contact and resistance is felt.
properly locked in place.
3. Pull contact-wire assembly out of connector.
Figure 7-15. HD/HDP Locking Contacts Into Position Figure 7-17. HD/HDP Unlocking Contacts
NOTE: For unused wire cavities, insert sealing plugs for full NOTE: Do Not twist or insert tool at an angle.
environmental sealing
3120772 – JLG Lift – 7-9

MAIN
VALVE
PLATFORM
CONSOLE
J11 JIB
J7 J8
J1 J6
VALVE
J2 J5
J4
J3
STEER /
BRAKE
VALVE
TO JIB
VALVE
ANALYZER
FOOT
SWITCH
PLATFORM
WORK
LIGHTS
RECEPTACLE
AT PLATFORM
Figure 7-18. Electrical Components - Sheet 1 of 2
7-10 – JLG Lift – 3120772

POSI-TRACK/ SPEED SENSOR

SPEED TILT MODULE (RIGHT BRAKE) BATTERY
SENSOR CHARGER
(LEFT BRAKE)
HORN
TO GROUND
CONTROL BOX
COVER
POWER
MODULE
(SHOWN HERE
FOR CLARITY)
CONTROL
MODULE
(SHOWN HERE
FOR CLARITY) BEACON
LIGHT
GROUND TO
CONTROL BATT.
BOX B–
TO
BATTERY
CHARGER
CONTACTOR
PLATE
PUMP/
MOTOR
BOOM
LIMIT
SWITCHES
Figure 7-19. Electrical Components - Sheet 2 of 2
3120772 – JLG Lift – 7-11

Figure 7-20. Electrical Schematic - Sheet 1 of 2
7-12 – JLG Lift – 3120772

1870225 A
Figure 7-21. Electrical Schematic - Sheet 2 of 2
3120772 – JLG Lift – 7-13

Figure 7-22. Hydraulic Schematic - 300A - Sheet 1 of 2
7-14 – JLG Lift – 3120772

2792521 B
Figure 7-23. Hydraulic Schematic - 300A - Sheet 2 of 2
3120772 – JLG Lift – 7-15

Figure 7-24. Hydraulic Schematic - 300AJ - Sheet 1 of 2
7-16 – JLG Lift – 3120772

2792522 B
Figure 7-25. Hydraulic Schematic - 300AJ - Sheet 2 of 2
3120772 – JLG Lift – 7-17

Figure 7-26. Hydraulic Schematic - 300AJP - Sheet 2 of 2
7-18 – JLG Lift – 3120772

2792523 B
Figure 7-27. Hydraulic Schematic - 300AJP - Sheet 2 of 2
3120772 – JLG Lift – 7-19

NOTES:
7-20 – JLG Lift – 3120772

3120772
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65 810122 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N. T. Italy The Netherlands
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 +31 (0)23 565 5665
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +31 (0)23 557 2493
(852) 2639 5797
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras JLG Sverige AB

UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 176 27 Jarfalla
+48 (0)914 320 245 Scotland 08755 Castellbisbal, Barcelona Sweden
+48 (0)914 358 200 Spain +46 (0)850 659 500
+44 (0)141 781 6700
+34 93 772 4700 +46 (0)850 659 534
+44 (0)141 773 1907
+34 93 771 1762
www.jlg.com

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Service and Maintenance Manual

January 23, 2009

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

3120772 – JLG Lift – A-1

Original Issue November 15, 2000

A-2 – JLG Lift – 3120772

SECTION NO. TITLE PAGE NO.

3120772 – JLG Lift – i

SECTION NO. TITLE PAGE NO.

ii – JLG Lift – 3120772

SECTION NO. TITLE PAGE NO.

3120772 – JLG Lift – iii

SECTION NO. TITLE PAGE NO.

iv – JLG Lift – 3120772

FIGURE NO. TITLE PAGE NO.

3120772 – JLG Lift – v

FIGURE NO. TITLE PAGE NO.

vi – JLG Lift – 3120772

FIGURE NO. TITLE PAGE NO.

3120772 – JLG Lift – vii

TABLE NO. TITLE PAGE NO.

viii – JLG Lift – 3120772

1.1 CAPACITIES Table 1-3. Operating Specifications - E300AJ

Maximum Travel Grade, stowed 5%

Horizontal Platform Reach 20 ft. (6.1 m)

Table 1-2. Operating Specifications - E300A Machine Width 4 ft. (1.22 m)

Machine Width 4 ft. (1.22 m) Table 1-4. Operating Specifications - E300AJP

Maximum System Voltage 48 VDC Vertical Platform Height 30 ft. (9.14 m

Machine Width 4 ft. (1.22 m)

Turning Radius (Outside) 10 ft. (3.05 m)

Turning Radius (Inside) 5 ft. (1.52 m)

Drive Speed (High Drive) 45-50 sec/ 200ft. (61 m)

Gross Machine Weight 15,800 lbs. (7167 kg)

Maximum System Voltage 48 VDC

Maximum Main Relief Hyd. Pressure 3200 psi. (220.6 bars)

3120772 – JLG Lift – 1-1

1.3 BATTERY CHARGER 1.7 HYDRAULIC PUMP/ELECTRIC MOTOR

1.4 DRIVE SYSTEM

Machine Length (stowed)

Platform Height 30 ft., 0 in. (9.14 m.)

Micron Rating 25 Micron

1-2 – JLG Lift – 3120772

1.9 FUNCTION SPEEDS 1.10 TORQUE SPECIFICATIONS

Speed Description Torque Value Interval Hours

Upper Lift Down 20-23

Boom Telescope Out

3120772 – JLG Lift – 1-3

Circuit PSI Bar

Platform Level Down Relief 1200 83 Telescope Cylinder 80 36.2

Steer/Brake Valve Lift Cylinder 103 46.7

Main Relief (A/AJ) 2500 172 Tower Lift Cylinder 68 30.8

Battery Box (includes batteries) 660 299.3

1-4 – JLG Lift – 3120772

Critical Stability Weights 1.15 HYDRAULIC OIL

3120772 – JLG Lift – 1-5

ISO Viscosity Grade #15 Type Synthetic Biodegradable

at 210° F 43 SUS Viscosity

cp at -30° F 3.200 at 40° C 37 cSt

Viscosity Index 140 at 100° C 8.4 cSt

Table 1-20. Mobilfluid 424 Specs

SAE Grade 10W30

1-6 – JLG Lift – 3120772

Figure 1-1. Operator Maintenance & Lubrication Diagram